Welding galvanized steel

by Adric Maggs
(Lismore NSW Australia 2480)

When welding galvanized steel (especially hot dipped) set the welder a bit hotter than normal & make sure you give a good "wiggle" between the two pieces being welded to help cut through the galvanizing to ensure a good weld pool at the start.Then take your time as you move along allowing time for the gal to burn away.Of course grinding the gal off is going to give the best results,but time can be saved by just welding it as is !

(Don't breathe fumes though,use a fan or fume extraction)

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Mar 11, 2014
Use caution NEW
by: Steve

In reference to the guy that said "If I have to weld galv I always bring some milk along it gets rid of the headache caused by galv fumes" -- if you are getting a headache, you're doing it WAY wrong. You are poisoning yourself. Metal fume fever is no joke, not something to mess around with. Clean the zinc off as much as possible, and ventilate the heck out of the area... do not breath ANY of the smoke. If you get headaches, you are doing very real damage to your lungs. Not worth it.

Mar 29, 2013
Removing Galvy before welding NEW
by: Hawaii Welder

Grinding discs made to grind aluminum work really well to remove heavy galvanized coating before welding. Always war a respirator. I use a 3m half mask with 3M P100 Particulate Filter with Organic Vapor Relief. Part number 2097. fits well under my hood.

Jan 03, 2012
Milk NEW
by: Lincoln 185

If I have to weld galv I always bring some milk along it gets rid of the headache caused by galv fumes

Dec 31, 2011
Welding galvanized steel NEW
by: Anonymous

Welding of galvanized steel is done almost exactly the same way as welding of the bare steel of the same composition.hot dip galvanized steel

Nov 14, 2011
MIG WELDING GALVANIZED STEEL NEW
by: Lucky Bastard

First rule- CLEAN IT!!!!!!
Second rule- CLEAN IT!!!!! (Seeing a theme here?)
HOT DIP- Use a 60 grit flap wheel. Using a hard wheel will just heat up the galvanizing and smear it all over the place, where the flap wheel will actually remove the galvanizing.
COLD GALVANIZE- Same drill as above.
WHY CLEAN IT?- 2 reasons, #1- Leaving the galvanized coating on there will make the weld look like ca-ca and make a spatter filled mess, not to mention foul the tip of the MIG gun something awful.
NOW THE BIGGIE (drumroll please) #2- YOUR LUNGS AND BRAIN DO NOT HAVE PART NUMBERS, AND YOU CAN'T JUST CALL MCMASTER-CARR OR GRAINGER AND JUST ORDER SOME MORE. THE GAS THAT IS EMMITTED DURING WELDING GALVANIZED MATERIAL IS POISONOUS AND WILL CAUSE LUNG AND BRAIN DAMAGE!!!!!!!!! PERIOD.
So do your lungs and brain a favor, and DO NOT weld galvanized ANYTHING without cleaning it first!

Nov 14, 2011
MIG WELDING GALVANIZED STEEL NEW
by: Anonymous

First rule- CLEAN IT!!!!!!
Second rule- CLEAN IT!!!!! (Seeing a theme here?)
HOT DIP- Use a 60 grit flap wheel. Using a hard wheel will just heat up the galvanizing and smear it all over the place, where the flap wheel will actually remove the galvanizing.
COLD GALVANIZE- Same drill as above.
WHY CLEAN IT?- 2 reasons, #1- Leaving the galvanized coating on there will make the weld look like ca-ca and make a spatter filled mess, not to mention foul the tip of the MIG gun something awful.
NOW THE BIGGIE (drumroll please) #2- YOUR LUNGS AND BRAIN DO NOT HAVE PART NUMBERS, AND YOU CAN'T JUST CALL MCMASTER-CARR OR GRAINGER AND JUST ORDER SOME MORE. THE GAS THAT IS EMMITTED DURING WELDING GALVANIZED MATERIAL IS POISONOUS AND WILL CAUSE LUNG AND BRAIN DAMAGE!!!!!!!!! PERIOD.
So do your lungs and brain a favor, and DO NOT weld galvanized ANYTHING without cleaning it first!

Dec 08, 2010
nasty stuff better off cleaning it to save your lungs.
by: Anonymous

Everything we weld is hot dipped galv'd. We found that grinding wheels just heat it up and move it around like a buffing compound and by the time you get it clean, you've lost most of the steel. Sanding disks that are made up of overlapping flaps of sand paper are the best to remove the galvy. 60 grit is the best because it doesn't eat as much steel as the 40.

Oct 21, 2010
re: welding galvanized steel
by: Anonymous

To reiterate with a word of caution. DO NOT BREATHE THE FUMES. They will make you very very sick. First sign is a blazing headache, then drooling like a fool. Something about the burned up zinc that makes you good & sick.

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