Steel ER90S-D2
ER90S-D2 is a higher-carbon, higher-strength Mn-Mo solid GMAW wire in the D2 family, depositing weld metal in the 90 ksi tensile class.
Reference datasheet — ER90S-D2 is not in the instant-quote catalog. Upload your part and an engineer will quote it in this grade or suggest the closest stocked equivalent.
Values for the AW condition
ER90S-D2 tempers and conditions
ER90S-D2 is supplied in 2 conditions, soft to hard. AW is the default FabDigit quotes; the values on this page are for it.
Compare all 2 conditionsHide
| Condition · open for datasheet | Best for | Yield MPa | Tensile MPa | Elong. % | Hardness | Conductivity |
|---|---|---|---|---|---|---|
Post-weld heat treated | Pick when the fabrication must be stress-relieved or PWHT'd; strength drops to the ER80S-D2 (550 MPa) level with improved ductility. | 500 | 600 | 26 | 11 HRC | 8.5 % IACS |
AWDefault As-welded deposit | Standard classification condition for ER90S-D2: use for 90 ksi-class joints that will not be post-weld heat treated. | 570 | 660 | 23 | 17 HRC | 8 % IACS |
Supply forms, finishes and certifications
Ways ER90S-D2 is supplied — form, process route, surface or paperwork — without a datasheet of their own. The property values above apply.
| Option | What it is | Type |
|---|---|---|
WIRE-CD | Cold-drawn copper-coated wire as supplied | Supply form |
What is ER90S-D2?
ER90S-D2 is a higher-carbon, higher-strength Mn-Mo solid GMAW wire in the D2 family, depositing weld metal in the 90 ksi tensile class. It is used to match high-strength structural steels and pressure vessel plate, and ships as cold-drawn, copper-coated spooled wire. Typical deposits give about 570 MPa yield, 660 MPa tensile, 23 % elongation and 210 HB, with service limited to roughly 400 °C. The deposit has no inherent corrosion resistance and can lose the 90 ksi class under long PWHT; drop to an 80 ksi D2 wire where the lower strength level is acceptable. ER90S-D2 has a density of 7.85 g/cm³ (0.284 lb/in³), heavier than 56% of steel grades. It melts at 1,470°C (2,678 °F). ER90S-D2 has a yield strength of 570 MPa (82.7 ksi) and a tensile strength of 660 MPa (95.7 ksi) — stronger than 74% of steel grades. Elongation at break is 23% and the elastic modulus is 205 GPa (29.7 Msi).
What is ER90S-D2 used for?
- high-strength structural steel welding
- heavy machinery fabrication
- pressure vessel welds requiring 90ksi weld metal
Advantages
- Readily welded — 90/100, better than 90% of steel grades
ER90S-D2 properties
Typical room-temperature values for ER90S-D2-AW; bars are the position among steel grades.
Physical3
ER90S-D2 has a density of 7.85 g/cm³ (0.284 lb/in³), heavier than 56% of steel grades. It melts at 1,470°C (2,678 °F).
Mechanical17
ER90S-D2 has a yield strength of 570 MPa (82.7 ksi) and a tensile strength of 660 MPa (95.7 ksi) — stronger than 74% of steel grades. Elongation at break is 23% and the elastic modulus is 205 GPa (29.7 Msi).
Thermal6
ER90S-D2 is rated for continuous service to 400°C (752 °F). It conducts heat at 42 W/m·K (24.3 BTU/hr·ft·°F), worse than 56% of steel grades. Thermal expansion is 12.5 µm/m·K (6.94 µin/in·°F).
Electrical3
ER90S-D2 conducts electricity at 8 % IACS, better than 55% of steel grades.
Chemical & Environmental3
Corrosion resistance is not recommended (12/100), worse than 53% of steel grades.
Sustainability4
Producing a kilogram of ER90S-D2 takes about 32 MJ of energy and emits 2.4 kg of CO₂ — more than 70% of steel grades. Typical recycled content is 30%.
Manufacturability7
ER90S-D2's machinability is fair (45/100, worse than 65% of steel grades); weldability excellent (90/100); formability fair (42/100).
Common Calculations5
Values are nominal handbook figures for design screening. Certified mill or lot data ships with every FabDigit order on request.
Strength versus weight in the steel family
Yield strength against density for every steel grade FabDigit runs. ER90S-D2 is highlighted; hover a dot for its name, or open the interactive family chart.
Working with ER90S-D2
Is ER90S-D2 easy to machine?
Deposited metal machines like normalized HSLA steel (~200 HB); use carbide tooling, expect harder spots at fusion boundaries and in unbuffered starts/stops.
Can ER90S-D2 be welded?
GMAW with CO₂ or Ar–CO₂/Ar–O₂; keep heat input, preheat and interpass temperature per the base metal's CE, limit moisture on the wire, and avoid long PWHT if the 90 ksi class must be retained.
Can ER90S-D2 be formed, bent or molded?
Not a formed product; the wire is cold drawn and copper coated — keep spools dry and avoid kinking to preserve feedability.
ER90S-D2 chemical composition (wt %)
Limits by weight percent from the governing specification, written the way the spec states them — a single maximum for impurities, a range for alloying elements, and the base element as balance. Nominal is the typical mid-range value.
| Element | Spec limit (wt %) | Nominal |
|---|---|---|
| C | 0.07 – 0.12 | 0.1 |
| Mn | 1.6 – 2.1 | 1.85 |
| Si | 0.5 – 0.8 | 0.65 |
| Mo | 0.4 – 0.6 | 0.5 |
| P | ≤ 0.03 | 0.01 |
| S | ≤ 0.03 | 0.01 |
| Niresidual | ≤ 0.15 | 0.05 |
| Crresidual | ≤ 0.15 | 0.05 |
| Vresidual | ≤ 0.05 | 0.01 |
| Cuincludes copper coating | ≤ 0.5 | 0.2 |
| Fe | balance |
What surface finishes work on ER90S-D2?
Weld metal has no inherent corrosion resistance: grind/blast and then paint, phosphate, metallize or zinc coat together with the base metal.
Surface treatments FabDigit runs on steel parts — pick them in the quote configurator or call them out on the drawing. Each links to its datasheet in the surface-finish library (thickness, specs, call-out, material verdicts).
Organic Coating
Black / Phosphate
Thermal Spray
Equivalent designations
Standards and trade names that resolve to Steel ER90S-D2 in FabDigit's catalog. Equivalence is nominal — check the exact specification when certification matters.
- Other
- ER62S-D2
How much does ER90S-D2 cost?
ER90S-D2 is a standard-cost steel ($$), cheaper than about 71% of the materials FabDigit quotes. Part price depends far more on geometry, tolerance and quantity than on the raw stock — upload a CAD file for a live quote.
ER90S-D2 — frequently asked
What is ER90S-D2 used for?
ER90S-D2 is typically used for high-strength structural steel welding, heavy machinery fabrication and pressure vessel welds requiring 90ksi weld metal. In short: 90 ksi Mn-Mo wire; strongest of D2 family; single-shield CO₂ capable.
What is the yield strength of ER90S-D2?
ER90S-D2 has a typical yield strength of 570 MPa (82.7 ksi) and a tensile strength of 660 MPa (95.7 ksi) — stronger than 74% of steel grades. Strength varies by condition: see the 2 listed tempers.
Is ER90S-D2 easy to machine?
Reasonably — machinability is rated fair (45/100, worse than 65% of steel grades). Deposited metal machines like normalized HSLA steel (~200 HB); use carbide tooling, expect harder spots at fusion boundaries and in unbuffered starts/stops.
Can ER90S-D2 be welded?
Yes — weldability is rated excellent (90/100). GMAW with CO₂ or Ar–CO₂/Ar–O₂; keep heat input, preheat and interpass temperature per the base metal's CE, limit moisture on the wire, and avoid long PWHT if the 90 ksi class must be retained.
What surface finishes work on ER90S-D2?
Weld metal has no inherent corrosion resistance: grind/blast and then paint, phosphate, metallize or zinc coat together with the base metal.
Can ER90S-D2 be formed, bent or molded?
Not a formed product; the wire is cold drawn and copper coated — keep spools dry and avoid kinking to preserve feedability.
What is the maximum service temperature of ER90S-D2?
ER90S-D2 is rated for continuous use to about 400°C (752 °F). Strength falls off well before that limit — check the elevated-temperature data for load-bearing parts.
What is the difference between ER90S-D2-AW and ER90S-D2 PWHT?
AW is the default condition — standard classification condition for ER90S-D2: use for 90 ksi-class joints that will not be post-weld heat treated. PWHT: pick when the fabrication must be stress-relieved or PWHT'd; strength drops to the ER80S-D2 (550 MPa) level with improved ductility. Yield strength is 570 MPa in AW versus 500 MPa in PWHT.
How much does ER90S-D2 cost?
ER90S-D2 is a standard-cost steel ($$), cheaper than about 71% of the materials FabDigit quotes. Part price depends far more on geometry, tolerance and quantity than on the raw stock — upload a CAD file for a live quote.
Sources
- AWS A5.28/A5.28M — Low-Alloy Steel Electrodes and Rods for Gas Shielded Arc Welding — AWS (2020)
- ASM Handbook Vol. 6 — Welding, Brazing and Soldering — ASM International (1993)
- ASM Handbook Vol. 1 — Properties and Selection: Irons, Steels — ASM International (1990)
- Mn-Mo solid MIG wire (90 ksi class) product data — Lincoln Electric / ESAB / Hobart (2023)
Property data is compiled from published supplier and standards handbooks and normalised for comparison; hardness values on non-Brinell scales are converted approximately for charting only. Manufacturability limits are FabDigit quote-engine defaults and may be relaxed by engineering review. Nothing on this page is a certification — request mill certs, CoC or material test reports with your order.