Welding zinc plated hardware

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I am wondering if you can weld zinc plated hardware to mild steel? Would there be any problem?
Reply:welcome to the site  lots of info hereyou really should grind...mill...turn the zinc out of the weld area as best you canwhat method are we using?...zap!
Reply:It's easy.  I do recommend you grind off the coating in the area to be welded because when it gets hot the smoke is toxic.  The zinc can also cause hot cracking.  6010 and 6011 are the standard electrodes for welding galvanized steel.  If you get it clean enough, 7018 can be used but the zinc coating penetrates deep into the steel and will mess with your arc a little bit, even if you think you ground it all off.
Reply:So basically zinc plated hardwares are mild steel that is coated with a layer of zinc, correct? How much do I need to grind down? Thanks.
Reply:If you grind, you will see a change in the metal's color.  The texture also changes a bit.  It's hard to tell you what color to expect because zinc coatings can be several different shades from almost golden to silverish...I think based on how it's applied.  Most I have seen is more silver.Others here have mentioned using muratic acid to remove the zinc.  This might be an option.  They said, when it stops foaming, it's gone...I havent done that, but it might be an option.Be careful...welding galvanized material is not a trivial safety issue.  You might want to check out other recent discussions about this.http://www.weldingweb.com/vbb/showthread.php?t=4638This thread provides some more detailed info and a variety of opinions and points of view on safety and methods.Last edited by smithboy; 03-28-2006 at 10:22 AM.Smithboy...if it ain't broke, you ain't tryin'.
Reply:You can also tell when you hit steel because steel sparks and the plating doesnt.
Reply:Thanks for the tips. I grinded the areas where it would be welded. It did not take much of grinding to get down to bare steel.