Welding galvanized steel can be a challenging task, as it requires a specific welding rod that can handle the unique properties of the material.
Galvanized steel is coated with a layer of zinc to protect it from corrosion, but this coating can also create challenges when it comes to welding.
Best Welding Rod for Galvanized Steel
Choosing the right welding rod is crucial for achieving a strong and long-lasting weld on galvanized steel.
In this blog, we will explore the best welding rods for galvanized steel and provide valuable insights to help you make an informed decision when selecting a welding rod for your project.
We’ll cover the important properties to look for in a welding rod, such as strength, flexibility, and compatibility with galvanized steel.
We’ll also discuss the different types of welding rods and their applications, as well as tips for welding galvanized steel safely and effectively.
What is Zinc Coating on Galvanized Steel?
Zinc coating, also known as galvanizing, is a process used to protect steel from corrosion.
In this process, a layer of zinc is applied to the surface of the steel, creating a barrier that shields it from the elements. The resulting material is known as galvanized steel.
The process of galvanizing involves immersing the steel in a bath of molten zinc, which adheres to the surface of the metal.
This creates a coating that is bonded to the steel, providing a durable and long-lasting protection against rust and corrosion. The thickness of the zinc coating can be varied to suit different applications and environments.
Zinc coating provides a number of benefits to galvanized steel. Not only does it protect the steel from corrosion, but it also provides a shiny, attractive finish.
Additionally, it makes the steel more resistant to scratches and other physical damage. Zinc is also an affordable and abundant material, making galvanizing a cost-effective way to protect steel.
It is a popular choice for outdoor applications due to its resistance to rust and corrosion.
Related Reading: Differences between stainless steel and galvanized steel
However, when it comes to welding, the zinc coating can present some challenges that require specific precautions and the use of the right welding rods to achieve a strong and reliable weld.
Welding Galvanized Steel
Welding galvanized steel can be a bit more challenging than welding other types of steel due to the presence of the zinc coating.
The zinc coating can release harmful fumes when heated, and these fumes can be dangerous if inhaled. Therefore, it is important to take proper precautions when welding galvanized steel.
To weld galvanized steel safely, it is essential to wear appropriate personal protective equipment, such as a respirator, gloves, and safety glasses.
You should also ensure that the work area is well-ventilated to prevent the buildup of harmful fumes.
Here are some tips for welding galvanized steel safely and effectively:
- Proper ventilation: It is important to have adequate ventilation in the welding area to prevent inhaling harmful fumes released by the zinc coating.
- Grind off the zinc coating: Before welding, it is recommended to grind off the zinc coating from the area to be welded. This will help to reduce the release of harmful fumes and improve the quality of the weld.
- Use the correct welding technique: MIG welding is the most commonly used welding technique for galvanized steel. It is important to use the correct welding technique, such as using a low amperage setting and a short arc length, to avoid burning off the zinc coating and producing fumes.
- Use the right filler material: It is important to use the right filler material for welding galvanized steel. Copper-coated steel filler materials are recommended as they help to reduce the formation of zinc oxide fumes during welding.
- Clean the welded area: After welding, it is important to clean the welded area to remove any remaining zinc coating and prevent corrosion.
Best Stick Welding Rod for Galvanized Steel
When stick welding galvanized steel, it’s important to choose the right type of welding rod to achieve a quality weld. Here are a few options to consider:
E6010 Welding Rod
The E6010 electrodes are known for their deeply penetrating and forceful spray type arc, along with a thin and easily removable slag that may not fully cover the weld bead.
When creating fillet welds using these electrodes, the weld face typically appears flat and features a somewhat coarse and unevenly spaced ripple.
The high cellulose content in the covering material, which often exceeds 30% by weight, is a defining characteristic of these electrodes.
Additional materials used in the covering include titanium dioxide, metallic deoxidizers like ferromanganese, various magnesium or aluminum silicates, and liquid sodium silicate as a binder. This electrode type is commonly referred to as the high-cellulose sodium type due to its composition.
E6010 is a cellulose-based electrode that can be used to weld both galvanized and non-galvanized steel. It has deep penetration and can be used in all positions. However, it requires a DC power source and must be used with a high amperage setting.
E6011 Welding Rod for Galvanized Steel
Similar to E6010, E6011 Welding electrode is also cellulose-based and can be used to weld both galvanized and non-galvanized steel.
It has good penetration and can be used in all positions. It can be used with both AC and DC power sources, and with a lower amperage setting than E6010.
The E6011 electrodes are specifically designed to be used with AC current, and their goal is to replicate the mechanical properties and usability characteristics of the E6010 classification.
While they can also be used with DCEP (electrode positive), you may notice a decrease in joint penetration compared to the E6010 electrodes. The arc action, slag, and appearance of fillet welds are very similar to those of the E6010 electrodes.
Like the E6010, the E6011 rod coverings contain a high cellulose content, which gives them their classification as the high-cellulose potassium type.
They also contain similar ingredients to the E6010 coverings, including metallic deoxidizers such as calcium and potassium compounds in small quantities.
E6018 Welding rod for Galvanized Steel
The E6018 electrodes share many of the same operating and mechanical properties as the E7018, albeit with a slightly lower strength level.
Additionally, the electrode covering and low hydrogen characteristics are quite similar.
The E6018 electrode is an excellent choice when a weld deposit that either matches or falls slightly below the intended strength level is needed.
7018 Welding rod for Galvanized Steel
E7018 Rod is a low hydrogen electrode that is typically used for welding non-galvanized steel, but it can also be used for galvanized steel.
It has good penetration and produces a high-quality weld. It can be used with both AC and DC power sources and can be used in all positions.