Which Welding Rod for Galvanized Steel
Galvanized steel is coated with zinc to prevent corrosion. Welding on galvanized metal vaporizes the zinc, creating toxic zinc oxide fumes that cause metal fume fever (flu-like symptoms lasting 24-48 hours). Safety precautions are mandatory. The zinc coating also interferes with the weld unless you account for it.
Recommended Electrodes
E6011
Best stick rod for welding galvanized steel. The cellulosic arc burns through the zinc coating and the slag helps float zinc contamination to the surface. Runs on AC or DCEP.
E6013
Acceptable for light galvanized material where the zinc layer is thin. The soft arc does not blast through zinc as aggressively as E6011, so more porosity may result on heavier galvanized coatings.
ER70S-6
MIG works on galvanized if you grind the zinc off the weld zone first. Without grinding, the zinc causes severe porosity and spatter. Significantly more prep work required compared to stick.
Technique Tips
CRITICAL SAFETY: Always weld galvanized steel with adequate ventilation or a supplied-air respirator. Position yourself upwind if outdoors. Standard cartridge respirators with P100 filters provide minimum protection. Supplied air is preferred for sustained work.
For best weld quality, grind the zinc coating off both sides of the joint for at least 1 inch beyond the weld zone. This eliminates zinc interference and fume generation. If you cannot grind, use E6011 with a longer arc length to let zinc fumes escape ahead of the puddle. Travel slightly slower to allow zinc to burn off before the puddle arrives. Expect more spatter than normal.
Common Mistakes to Avoid
Welding galvanized steel in an enclosed space without ventilation. Zinc fume fever is debilitating and exposure is cumulative. Using E7018 on unground galvanized surface, which produces severe porosity because the low-hydrogen coating cannot handle the zinc contamination. Assuming the zinc coating provides corrosion protection after welding. The heat destroys the coating in the weld zone, requiring cold galvanizing paint on the finished weld.
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