Keep in mind that removing the zinc coating can be as hazardous as welding over it. This should be limited to thin section as vertical down welding produces shallow penetration. In many cases this means you will be welding vertically with a downward progression. In most cases, removing the zinc coating from the joint ends reduces overall costs because it also eliminates rework.Īnother way to reduce the costs associated with removing spatter is to position the part in such a way that the spatter does not hit the part or rolls off it. It should also eliminate porosity, cracking and lack of fusion. In some cases the latter is done regardless of whether or not the coating was removed prior to welding.Īlthough it adds one or two operations it will eliminate or at least drastically reduce spatter and spatter clean up. This adds two operations: removing the coating and re-spraying or painting the weld seam after welding to regain corrosion resistance. The best way to weld galvanized steel, regardless of welding process, is to remove the zinc coating from the joint.
#FLUX CORE WELDING GALVANIZED STEEL HOW TO#
Below are a few recommendations on how to weld on galvanized steel.Īny Arc Welding Process – General Recommendations This is a big claim and these filler metals certainly have some merit, but there are other practical ways to successfully weld galvanized steel. Manufacturers of filler metal have come up with special wires that promise to eliminate porosity. Porosity is almost inevitable and is affected mainly by the thickness of the zinc coating. Although the weld burns off the zinc, very little if any corrosion resistance is lost, especially in thin section (sheet metal). The heat of the arc will burn off the zinc coating without problems however, the resulting weld may present many issues such as excessive porosity, unacceptable bead appearance, lack of fusion, cracks and excessive spatter. The challenge is welding over the zinc coating. It is a great process to prevent corrosion. Galvanized parts are used in a wide variety of industries including automotive, structural steel, construction, oil field and many more.
This problem can be resolved following basic recommendations. The zinc coating on galvanized parts can produce excessive amounts of spatter.
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