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Weld Star ER120S-G High Strength TIG Filler Rods 1.6mm 5kg

£68.00 ex VAT

Further Reductions Available On Request 01276 505012

  • Low Temperature
  • High Strength
  • 1.6mm 5kg Pack




A 5KG Pack of Weld Star 1.6mm ER 120S-G high strength TIG filler wire. Copper coated wire with a combination of Nickel(Ni), Chromium(Cr) and Molybdenum(Mo). Specifically designed for the welding of ultra-high strength and fine grain steels (with a yield strength above 890MPa).  In particular when welding high yield strength steels similar to HY-100, the finished weld exhibits good mechanical properties including excellent impact resistance even at low temperatures.

The addition of manganese ensures a decrease in brittleness, which increases the levels of impact resistance and strength.  The silicon content enhances deoxidisation and impurity removal. Chromium content provides excellent corrosion resistance to issues such as hot sulphide corrosion and hydrogen attack. Further protection from corrosion is imparted by the molybdenum content.

Weld Star ER 120S-G filler rods have high impact strength particularly at low temperatures. Combined with outstanding levels of plasticity in the weld deposit allowing bending and misshaping without incurring failure of the welded joint.

Typical applications include welding of lifting and handling machinery, bridges, tanks, transport, shipbuilding, railway, mining, cranes and frames. Extensively used for high yield strength steels such as HY-100 and similar. Due to its resistance to cold cracking it is also used for joining in large vehicle manufacturing. ER120S-G wire is also ideal for applications involving high strength pressure vessels and some heat treatable steels.

Features & Benefits
  • Good levels of ductility.
  • Excellent impact resistance and toughness.
  • Contains Nickel(Ni), Chromium(Cr) and Molybdenum(Mo) for improved mechanical properties.
  • Excellent resistance to corrosion.
  • Use for single and multiple pass applications.
  • Great capacity to withstand cracking.
What is the MPa Measurement?

MPa (Mega Pascal) is a standard measurement of pressure / tension and the strength of materials as defined in the International System of Weights and Measures.  See below for the acronym break down:

M = Mega (Standard matrix prefix meaning one million).

Pa = Pascal (From the surname of the inventor of the measurement – Blaise Pascal)

The Difference between Yield Strength and Tensile Strength

Yield Strength refers to determining the maximum amount of stress which can be applied before permanent shape change.  Tensile strength defines the amount of load or stress a material can handle until it stretches or breaks. Tensile strength is also used to identify the point at which steel moves from elastic(temporary) to plastic(permanent) deformation.

What is fine grain steel?

Low carbon content steels which contain micro-alloying elements (e.g. nickel, chromium, niobium or titanium) are often referred to as fine grain steels. As the name suggests, they have a fine grain structure which provides high levels of purity and toughness.  These steels also exhibit outstanding weldability and bending possibilities.  Due to their lightweight nature, they are used extensively in frame structures and axle construction for vehicles, plus components for mobile cranes.


Suitable for the following applications and industries:

  • Lifting and Handling Machinery
  • Vehicle Frames and Axle construction
  • Shipbuilding
  • Mobile Crane Components
  • Railway Industry
  • High Strength Pressure Vessels
  • Earth Moving Equipment
  • Mining Industry

The above applications are not an exhaustive list.

Chemical Composition % (Typical)
C% Si% Mn% P% S% Cu% Cr%
0.110 0.70 1.90 <0.015 <0.015 <0.25 0.50
Ni% Mo% Al% V% Ti% Zr%
2.50 0.50 <0.010 <0.030 0.08 <0.050


Mechanical Properties (Typical)
Tensile Strength 1040 MPa
Yield Strength 960 MPa
Elongation 16%
Impact Strength 60 J
Test Temperature -40ºC

Mechanical properties are approximate and may vary based on the heat, shielding gas, welding parameters and other factors.


EN ISO 16834-A – Mn4Ni2,5CrMo
AWS A5.28 – ER 120S-G


Shielding Gases

EN ISO 14175 – TIG: I1 (Argon)


Welding Positions

EN ISO 6947 – PA, PB, PC, PD, PE, PF


Typical Base Materials

S890QL, S960Q ; P460NH, P460NL1 ; Weldox 900, Weldox 960, Strenx 960*
* Illustrative, not exhaustive list


In Conclusion

As detailed above Weld Star (ER120S-G) high strength TIG filler wire has excellent mechanical properties and designed specifically for use with fine grain steels.  Combining excellent mechanical properties such as increased levels of strength, toughness and impact resistance, plus good levels of corrosion resistance. Even with the strength specific qualities previously mentioned,  ER120S-G TIG wire also poses excellent ductility and can withstand intense pressure without affecting the weld quality.

Green wire is produced using virgin raw materials sourced from specialised steel mills, which ensures consistent reliability and quality.

Wire images are for illustration only.


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