How to Weld Galvanized Steel

Welding galvanized steel is a fairly simple, straightforward process, but there are a few
things you should understand before attempting to do it. Here are some steps and
warnings that will help you if you need to join two pieces of galvanized steel together.

Steps

1
Understand the metal you are working with. Galvanized steel has a zinc coating or
plating to protect it from corrosion. There are two basic types of galvanizing, and for
welding purposes, some minor, but significant differences. These are:

Electroplated galvanize has a (generally) thinner zinc coating, which will allow for a
cleaner weld with less burn off and splatter.

Hot dipped galvanized steel has a thicker plating, since the steel has actually been
submerged in molten zinc. This coating will burn away during welding, but will leave a
dirtier weld and weld area, and require slightly more amperage for sufficient penetration.
2
Set up your welding machine. For most purposes, a 150 amp AC SMAW or arc welder
will weld galvanized steel. You will need to set up the amperage according to the
thickness of the metal and the diameter of your rods. A 1⁄8 inch (0.3 cm) 6011 rod will
run about 90-110 amps, smaller rods, slightly lower amperages, larger rods, higher.
3
Prepare the metal to be welded. Assuming you are joining two pieces, fit the parts to be
welded so there is a minimum gap. Grind a weld prep, or bevel on edges of metal
over 1⁄4 inch (0.6 cm) thick to recieve the filler metal during the weld and to insure full
penetration.
4
Grind away the zinc coating at the site of the weld. This is helpful in striking and
maintaining a steady arc, but isn't critical if you are dealing with a thin galvanized
coating and using appropriate rods. Still, since the galvanized coating will be burnt away
during the weld anyway, there is no real harm in removing it prior to welding if it is
practical.
5
Choose an appropriate rod. For coated metal like galvanized steel, a 6011 rod will give
good results without having to clean the weld joint. For high strength rods like E7018,
you will find cleaning down to the steel very helpful, since these rods must either be
used at high amperage or you will need to endure a lot of sticking as the combined slag
and burnt zinc will cause this.
6
Make sure you have plenty of fresh air while welding. Using a fan or welding outdoors
where there is a slight breeze will drift the combustion fumes away from you is a good
idea. If you are welding in a confined space (never recommended in any circumstance),
you may need a respirator capable of filtering out the particulates produced during
welding.
7
Trial weld a small piece of the same metal you are welding together to practice. Since
galvanized steel behaves slightly differently from regular mild steel, it may take a little
practice to get used to the larger, more plentiful sparks you will create while welding,
and the slightly slower welding speed required to allow the zinc to burn out of your way.
8
Go ahead and weld your metal. Strike your arc, hold it in position to maintain a good arc
flame, and move along the weld path sweeping the electrode slightly side to side to
create a neat weld.  Make subsequent passes if you cannot fill the whole weld prep in a
single pass, rather than overheating the metal trying to finish in a single pass.
9
Clean the slag and zinc oxide (a light grey to white powder residue along the weld)
between each pass and after your are finished, then grind the weld smooth, if required.
10
Coat the weld with a zinc rich primer after the metal has cooled and been cleaned. This
won't equal the corrosion resistance of the original galvanized coating, but it will help.
Tips
1. Use clean, fresh rods when welding, as rods that have absorbed moisture will not
perform well. Keep your welding rods in a sealed container when not in use.

2. Attach your ground clamp in a place where arcing won't show, and clamp it
tightly, since it may arc and burn through the galvanize coating otherwise.

Warnings
1. The smoke and fumes produced while welding galvanized steel are mildly toxic,
avoid breathing them if possible. Drinking milk can alleviate the symptoms of
galvanize poisoning.

2. Use a face shield when grinding or chipping welds.

3. Make sure your welding hood is the correct lens darkness for welding.
Welding galvanized steel
Fume extraction must be addressed, and a post-weld coating
may be needed
Oct 1, 2008Welding Design

Q: I have a fabrication shop and have been having

difficulty welding some galvanized steel. I have been
told to use a stainless steel welding electrode and
then I would not have to paint after welding. What is
your opinion?
A: When welding galvanized DO NOT use an austenitic
stainless steel welding electrode.
The zinc in the galvanized steel coating will be swept to the
center of the weld during solidification resulting in a
centerline crack. The amount of cracking will be dependent on
the thickness of the coating and how much is brought into the
weld.
Depending on the strength requirement of the weldment, the
best choice would be to use a silicon bronze (Er-CuSi-A)
electrode.
The zinc is soluble in the copper-based material, and should
yield a weld with minimal porosity. The minimum tensile
strength will be 50 ksi according to AWS A5.7.
If slightly higher strength is required, an aluminum bronze
(Er-CuAl-A2) electrode may be used. That would yield a
minimum strength of 60 ksi.
If you are going to be using the gas metal arc welding process
you should use 100 percent argon shielding gas with either
wire.
Another benefit to using these electrodes is that on thinner
materials there is a lower burn-though tendency that is due
mainly to the differential in melting temperatures between the
steel and the copper based fillers.
Mild steel fillers also may be used, such as an ER70S-3 filler
metal for gas metal arc welding. Elevated spatter levels along
with increased tendencies for porosity generally are
experienced.
Weld joint fit-up that is looser, yielding an alternate path for
the vapor that is generated from the zinc can be effective in
reducing the tendency for porosity. Additionally, welding
technique and welding procedure can be effective in reducing
porosity tendencies by using the arc heat to “burn” off the zinc
ahead of the weld.
The region adjacent to the weld toes will have exposed
surfaces because the arc heating has removed the zinc layer,
and may be prone to corrosion regardless of filler metal
selection.
A weld made with the silicon bronze or aluminum bronze will
be cathodic relative to the mild steel, resulting in accelerated
corrosion locally along the weld toes in a moist environment.
Depending on the environment, the weldment most likely will
require a post weld coating such as a paint containing zinc.
When welding galvanized, it is important to use proper fume
extraction.
A good article on the internet about welding galvanized, post
weld coatings and welding fumes can be found at the
following
website: www.sperkoengineering.com/html/articles/Welding
Galvanized.pdf.
Additionally, there is excellent information on welding safety
at Lincoln Electric's website at the following
link: www.lincolnelectric.com/community/safety.

This column is sponsored by Penton and the Lincoln Electric

Co., Cleveland. Dave Barton is a senior welding engineer in
the Application Engineering Group of The Lincoln Electric
Co. He oversees welding procedure development for both
new technology and existing products, performs failure
analyses for customers, and serves as a consultant on
welding application problems. Barton has been with Lincoln
Electric for 21 years. Send your questions for Mr. Barton in
care of WM by e-mail to:askdav@penton.com.
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