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Can You Weld Galvanized Steel to Mild Steel?

Can You Weld Galvanized Steel to Mild Steel?

If you’re a metalworker, welding is an essential part of your craft—but it isn’t always easy. One of the common problems faced by metalworkers is welding galvanized steel to mild steel, as it presents a few complications that you need to be aware of. In this blog post, we’ll discuss the basics of welding these two metals together, including the best practices and potential issues that may arise.

What Is Galvanized Steel?

Galvanized steel is steel that has been coated with zinc oxide in order to protect it from corrosion and rust. The process of galvanizing steel involves dipping the material into molten zinc or using electrolysis to apply a thin layer of zinc oxide directly onto the surface. This coating helps improve the lifespan of the material and makes it more resistant to water damage and other environmental factors.

Zinc oxide can react with certain materials when heated, which can create hazardous fumes or smoke. For this reason, extra care must be taken when welding galvanized steel in order to ensure that everyone in the vicinity stays safe.

Welding Processes for Galvanized Steel

The most common method for joining galvanized steel to mild steel is MIG (inert metal gas) welding, although TIG (inert tungsten gas) and oxy-acetylene processes can also be used if necessary. MIG welding has become increasingly popular due to its ease of use and its ability to quickly join two pieces together without creating too much heat or distortion on either piece. It is important to note that any welds made on galvanized steel should be done at lower temperatures than normal so as not to burn off any protective coatings or release harmful fumes into the air.

Using Shielding Gases When Welding Galvanized Steel

When working with MIG welders, shielding gases are used in order to protect the weld from contamination caused by oxygen or nitrogen present in the atmosphere. Argon-based shielding gases are recommended for use when welding galvanized materials because they provide better protection against oxidation than other shielding gases like argon/CO2 mixtures or carbon dioxide alone. It is also important to note that some welders may require special ventilation systems in order for them to work safely with galvanized materials due largely in part because of their sensitivity towards high concentrations of hydrogen-based materials like water vapour and hydrocarbons found in regular air at room temperature.


In conclusion, it is possible for you to weld galvanized steel onto mild steel, but there are certain precautions you need to take first before attempting such a task. Make sure that you have all the safety equipment needed before beginning your weld, and be sure that your welder uses an appropriate shielding gas, such as argon-based gases, whenever possible when working with galvanized materials. With proper preparation and cautionary steps taken beforehand, you will ensure successful results every time!

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