Weld galvanized steel is challenging, but not impossible for a beginner. There are plenty of things you can do to make it more manageable. If you have got experience with other welding processes like oxy or acetylene, then weld galvanized steel shouldn’t be any different. The challenge lies in the characteristics of galvanized steel. It’s strong but also brittle and has a high resistance to corrosion from moisture, oxygen, and saltwater. This means that it’s likely to crack or peel when welded using standard techniques. There are ways to mitigate these problems when welding galvanized steel at home without hiring an expertise welder.
What is galvanized steel?
Galvanized steel is a type of steel that has been coated with zinc to protect it from rusting. This coating is what gives galvanized steel its distinctive shine, although it also makes it more difficult to weld. Most galvanized steel is coated with iron, although there are other alloys available. Galvanized steel is mostly used in construction and around water, since it resists rusting while still being strong enough to withstand weathering in harsh conditions. There are also a variety of decorative coatings available that create different effects like shiny metallic colors or a distressed look with a matte finish. This can make it a popular choice for DIY garden projects or decorative fencing.
Choose the right equipment for welding galvanized steel
Before you can weld any galvanized structure, you will need to get the right equipment for the task. As discussed above, welding galvanized steel is challenging. To make it more manageable, you will need to use an autogenous welder. An autogenous welder is a gas welding machine that uses an onboard filler to weld the two metals together and prevent cracking. An autogenous welder is the best option for weld galvanized steel because it enables you to use a continuous filler wire rather than the standard pulse welder setup. This means that the weld is less likely to crack and you should have fewer problems with it corroding.
Techniques for welding galvanized steel
When it comes to welding galvanized iron, there are a number of challenges that you will need to overcome. The most important is that the two metals have different characteristics. While iron is strong and resistant to corrosion, it’s also brittle and can easily crack. With a coating of zinc, galvanized steel is strong and resists corrosion, but it’s also brittle and prone to cracking when welded. Having a good understanding of these differences will help you decide which welding approach is best for your project.
- Galvanized steel can be welded using either submerged or exposed arc welding. The main difference between the two is that submerged arc welding produces a weld with a smooth surface, while exposed arc welding produces a wider weld with a rough surface.
- Galvanized steel can also be welded using gas or shielded-gas welding. Gas welding produces a weld with a smooth surface and good corrosion resistance, but it’s much more likely to produce corrosion than shielded-gas welding.
- Galvanized steel can also be welded using tungsten-cathode or solid-state welding. SS welding produces an alloy weld with good corrosion resistance, but it’s less likely to be able to weld galvanized metals.
How to Weld Galvanized Steel?
- Choose a weldment. You will need a welder to weld galvanized steel. This could be a dedicated welder or perhaps a welder on a metal fabrication line. Regardless, you will need a welder that’s capable of welding the two different types of metal.
- Get the correct shielding gas. Shielded-gas welding requires a shielding gas to protect the weldment from the Gases produced by the arc. This gas is flammable so it should be stored inside a shielded container.
- Adjust the welding parameters. Shielded-gas welders have a variety of parameters that can be adjusted to control the welding process. Ensure you adjust these to control the process and protect the weldment.
- Check the weldment. Once the weld is complete, you will need to inspect the weldment to ensure it’s free from defects. If there are any defects, they should be smoothed using a grinder or file.
- Clean the weldment. Once the weld is inspected, it should be cleaned using a grinder or file. This will smooth the surface and remove any weld defects that may have been detected.
Take Steps to Make Things Easier
a. Use a continuous feeder. The biggest challenge when welding galvanized steel is that it’s prone to cracking. Cracking can occur during welding, during welding cleanup, or during inspection. To reduce the risk of damage and cracking, use a continuous feeder to feed the weldment. This will protect the weldment from damage during welding and make inspection easier.
b. Use a shielded-gas welding machine. Using shielded-gas welding reduces the risk of welding galvanized steel. This is because the weldment is more likely to be protected from the other elements during welding and less likely to crack. Shielding gas is flammable so it should be stored inside a shielded container.
Tips for Successful Welding Galvanized Steel
Use a continuous feeder: The best way to protect the weldment to use continuous feeder. This will protect the weldment from damage while welding and make inspection easier. Use shielded-gas welding. Shielded-gas welding can protect the weldment from the elements while welding and is relatively easy to control. This makes it a good option for welding galvanized steel.
Make sure you adjust the welding parameters. Once you have got the welding parameters adjusted, they should produce a weld with good corrosion resistance and be relatively easy to control. Weld the weldment. Welding galvanized steel is challenging and should be done using a dedicated welder.
Inspect the weldment. Inspect the weldment for any defects once it’s been welded. Inspect for cracks and smooth the weldment using a grinder or file. Clean the weldment. Once the weld has been inspected, the weldment should be cleaned using a grinder or file. This will smooth the weld and remove any weld defects that may have been detected. Remove the weldment from the welding tank. Once the weldment is clean, remove it from the welding tank and place it on the ground.
