Welding galvanized steel

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I bought a carport with galvanized steel tubing that is around 11 gauge. I want to weld the tubing. It has an insert to connect the two pieces of square tubing together using screws but I want to weld it to make it stronger and to reduce the number of anchors I would need. The weld will be a butt weld and the insert can act as a backing plate. I do not know what process to use. Stick will probably burn through. Should I MIG or flux core?  I will use a lincoln 140. Should I grind off the galvanized metal? If so, how far back?  What respirator filter should I use?  Can I use flux core with a fan and stay upwind without a respirator?Sent from my iPhone using Tapatalk
Reply:You will need to do a lot more prep of removing the galvy if you mig weld it. usually just a PIA.I would get some Fluxcore and weld it up.http://www.sperkoengineering.com/htm...Galvanized.pdfEd Conleyhttp://www.screamingbroccoli.com/MM252MM211 (Sold)Passport Plus & Spool gunLincoln SP135 Plus- (Gone to a good home)Klutch 120v Plasma cutterSO 2020 benderBeer in the fridge
Reply:Fumes from welding galvanized metal are highly toxic.  As I recall the correct respirator filter is the purple one.The only process that I'm aware of that does not require you to remove the galvanized coating first is to use silicon bronze MIG wire. Otherwise you need to grind off the galvanized coating (and still wear a respirator).Miller Trailblazer Pro 350DMiller Suitcase MIGMiller Spectrum 2050Miller Syncrowave 250DXLincoln 210MP
Reply:

Originally Posted by scsmith42

Fumes from welding galvanized metal are highly toxic.  As I recall the correct respirator filter is the purple one.The only process that I'm aware of that does not require you to remove the galvanized coating first is to use silicon bronze MIG wire. Otherwise you need to grind off the galvanized coating (and still wear a respirator).
Reply:You could use stick to weld it, 11 gauge is almost 1/8th so its not like we're talking autobody thickness, some 3/32 7018 or 7016 would do the job.If you do use MIG i'd be going for self shield flux core, it's become my new favourite process for welding pained, galvanised and rusty steel, some .035 E71T-11 (NR211mp or equivalent) would do the trick nicely I think.If you do weld it, wear a respirator for sure, zinc poisoning is no joke, it's carcinogenic which is bad enough, but it will also make you incredibly sick short term as well.
Reply:

Originally Posted by scsmith42

Fumes from welding galvanized metal are highly toxic.  As I recall the correct respirator filter is the purple one.The only process that I'm aware of that does not require you to remove the galvanized coating first is to use silicon bronze MIG wire. Otherwise you need to grind off the galvanized coating (and still wear a respirator).
Reply:If you are gonna stick weld, use 6010. That'll burn through it but smoke like hell. You'll have white flaking too. Never ever considered 7018. No idea what it would do. Sent from my iPhone using Tapatalk
Reply:Question---Why not just drill a hole through insert, upper and lower pieces and use through bolts? Stronger than screws and you can disassemble it when it flies off or collapses.
Reply:I would just stick weld it with 6010 and stay upwind or hold my breath momentarily when immersed in fumes. Zinc isn't THAT toxic, not like it's cadmium or something...Yeah, I heard about the guy who died from it, but he was cooking something like 16 tons of galvanized sh!t in a ceramics kiln or something stupid like that, and he probably inhaled 40 pounds of zinc...not recommended.Last edited by Kelvin; 9 Hours Ago at 06:28 PM.
Reply:Your looking for a more secure bond, just 6010 that sucker on 1 side and be done. Your not doing a structural weld.Sent from my SM-G960U using Tapatalk
Reply:around the turn of the mellinium,  was the tabbacco  settlements/payouts, and the public schools in my area were putting up fences/roll gates galore.   so i welded alot of galv., which got powder coated.     so, i'd do it outside upwind or fan like u say ,  and .035 nr211.    it couldnt hurt to wire wheel it while drinking a milk befroe.     if u gettin a purpleish radical puddle, then gotta go to plan b , but the galv usually aint that thick on the stuff ur talkinLast edited by 123weld; 8 Hours Ago at 07:26 PM.
Reply:Remember the garage is engineered (and probably any warranty) based on using screws. Welding could weaken the tube or make the structure too stiff for wind load. Grinding off galvanize could cause rusting. If you are asking about how to weld it, there is a chance you may burn through and create holes. I would think a long time before welding. Not everything is better by welding.Burt _____________________Miller Syncrowave 250Millermatic 211Miller 375 Plasma Cutter Hobart Handler 12010FtDrillBit.com
Reply:

Originally Posted by wb4rt

Remember the garage is engineered (and probably any warranty) based on using screws. Welding could weaken the tube or make the structure too stiff for wind load. Grinding off galvanize could cause rusting. If you are asking about how to weld it, there is a chance you may burn through and create holes. I would think a long time before welding. Not everything is better by welding.