Welding zinc pllated casters

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I need ot weld the zinc coated base plates for casters to a structure I built out of mild steel. Are there any special considerations for zinc to mild steel and the casters are ball bearing swivel with no apparent plastic or rubber parts. Do you all think the casters can take the heat? Thanks for the time and advice.
Reply:grind the zinc and use small rods (3/32). i would use 6010 but 7018 would be ok as well
Reply:Muratic acid will remove the zinc very quickly.Welding/Fab Pics: www.UtahWeld.com
Reply:I agree with some light grinding, however if you want to weld over zinc plating for the thin caster base plates, you can.  You wont hurt anything but produce more smoke and white colored zinc soot over the weld bead.  No biggy, just brush off with wire brush.  Just do NOT inhale that nasty zinc smoke.  Also, when the casters were made, it's more than likely what's called "blue" or "clear" (silver color).  The colors are what's called "chromate conversion coating."  It's either Tri-chrome or Hex-Chrome.  If it's Hex-chrome (hexavalent chromium), you do not want to breath the smoke plume at all.  Unless you're experienced in the field of zinc plating, most people can't tell the difference by looking at the finish.  So, moral of my long winded storey........ To play it safe, don't breath zinc fumes.  They could be  1)  bad without the hex-chrome coating.  Or they could be 2) really really bad with the hex-chrome coating.  Do I weld over zinc plated parts?  Yes, all the time for small welds like casters and such as you mentioned.  I just make sure I hold  my breath and/or I'm "up wind" of the weld plume just to play it safe.Lincoln Power Mig 216Lincoln AC/DC-225/125Miller  625 X-Treme PlasmaMiller 211 Forney 95FI-A 301HF 91110Victor Journeyman O/PMilwaukee DaytonMakita  Baileigh NRA Life Member
Reply:Zinc smoke is very irritating to the lungs and causes a condition known as "metal fume fever." It's like having the flu. Basically, the body reacts to Wear a respirator or use a fume evacuator. (In a pinch a good sized shop vac can be used to suck fumes.) Open up all your doors and windows when you're welding the stuff. If you try to weld through the zinc plating you'll get more spatter and your welds will look crappy and irregular.Grind the plating off in the weld areas, first. Once you grind the zinc off things tend to run a lot smoother and cleaner.Better yet, see if you can buy casters that aren't plated. You'll be a lot more productive that way.Last edited by Joshfromsaltlake; 05-26-2012 at 08:29 AM.
Reply:Breathing the dust and fumes from gringing it is as bad if not worse, You won't get metal fume fever from tacking a couple of casters on. If you are arc welding it and you want to feel better put a fan next to it. Not so good if your Migging it. Anyway turn up the heat, open the doors and weld it up."Si Vis Pacem Para Bellum"Lincoln Idealarc 250 AC/DCMillermatic 251   Syncrowave 300   30A spoolgunLincoln MP210Hypertherm 45(2) LN 25(2) Lincoln Weldanpower 225 CV(4) SA200   1 short hood    SA250    SAM 400