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When welding carbon and low-alloy steels, an ER80S-D2 low-alloy solid wire provides higher tensile and yield strength. This wire delivers quality welds matched to meet the requirements of many high-strength applications, such as welding construction equipment, pipe, trailers and more. The “D2” designator indicates that this wire is a manganese-molybdenum alloy. Manganese is a deoxidizer that makes this wire a good option for rusty or dirty metals while also helping increase tensile strength. Molybdenum also offers hardenability in addition to high-temperature strength.

Higher alloy content in ER80S-D2 wire can make the arc in a spray-transfer mode slightly more difficult to control, resulting in increased spatter. To combat this issue, welding operators may prefer to use a pulsed-GMAW process instead.

Copper-Free Solid Wire

Most solid welding wires contain a small amount of copper plating, which helps prevent wire corrosion and enhances electrical conductivity between the contact tip (also copper) and steel base material. Adding copper to certain steel base materials, however, can cause problems. Here, welding operators may prefer copper-free wire.

One benefit to copper-free wire: It can be used at a slightly lower voltage in spray-transfer mode as compared to the same wire with copper plating. For thinner materials, spray-transfer mode allows for quicker welding and a better deposition rate than short-circuit welding. This process change helps reduce spatter and minimize heat in the arc, thus lessening the chance of burnthrough.

When using a copper-free wire, be sure that the spool or coil of wire isn’t stored for long periods of time in the shop or on the jobsite, as the absence of copper can cause the product to rust. Copper-free wire may also cause arcing between the contact tip and base material should the surface finish or lubricant be incorrect. To defend against this problem, the welding operator may need to adjust welding parameters. 

Many Options for Solid-Wire Use

As with any welding operation, finding the right filler metal is key to gaining good productivity and quality, while also minimizing costs. Solid wires offer versatility in many general fabrication applications that require the welding of mild and low-alloy steel. Take care to select the right classification of wire for the job—based on desired mechanical and chemical properties—and to consult with a distributor or filler-metal manufacturer for assistance when in doubt.  MF

Industry-Related Terms: Plate, Scale, Shielding Gas, Spatter, Surface, Tensile Strength, Transfer, Penetration, Alloys, Conductivity, Hardenability
View Glossary of Metalforming Terms


See also: Hobart Brothers Co.

Technologies: Welding and Joining


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