Data shows that during the welding process, up to 50 grams of zinc vapor may be released per kilogram of galvanized steel, which poses a challenge to the quality of the weld, the health of personnel, and the operating environment.

The simplest and most effective way to reduce the impact of zinc vapor is to use low-hydrogen welding rods and pulse welding technology.

According to research, the corrosion rate of galvanized steel after welding is more than 40% higher than that of the un-welded area. The problem is not just cosmetic; corrosion can affect the stability of the overall structure.

To restore the corrosion protection in the weld area, it is recommended to supplement it with zinc spray coating, hot-dip galvanizing or cold spray technology. These methods can effectively restore the zinc coating in the weld area, improve its corrosion resistance and extend its service life.

The difference between hot-dip galvanizing and electrogalvanizing welding: why you can't use one for all

When it comes to welding galvanized steel, the requirements for hot-dip galvanizing and electrogalvanizing can be very different.

Hot-dip galvanized steel usually has a thick zinc layer and can easily produce a large amount of zinc vapor during the welding process. This can not only damage the quality of the weld, but also make the welding environment unsafe.

Hot-dip galvanized steel releases 2-3 times more zinc vapor during welding than electrogalvanized steel. This means that the welding process may be more difficult and even produce more defects if appropriate measures are not taken.

For hot-dip galvanized steel, CO2 shielded welding or pulsed welding is ideal. Not only does it reduce the build-up of zinc vapors, it also maintains the quality of the weld.

Especially when welding thicker galvanized steel, many people often ignore the damaging effect of the heat-affected zone on the zinc layer during welding.

When welding galvanized steel, the bond between the zinc layer and the steel base will quickly deteriorate once the welding temperature exceeds 300 degree , increasing the risk of weld cracking.

To avoid welding defects, it is essential to control the welding temperature. By controlling the temperature appropriately, not exceeding 300 degree , and using a dedicated coating remover, welding defects can be avoided and the overall quality can be improved.

Prolonged exposure to zinc vapor may cause acute poisoning in workers, manifested by symptoms such as dizziness, nausea, and difficulty breathing, which may be life-threatening in severe cases.