Galvanized steel is a tricky material to weld. I learned a lot through my research on the coated metal such as why it’s used and how it’s coated. Typically coated steels are used on parts that would be exposed to weather such as a swing set on the school playground. Though my research told me many things, the hands on perspective of a weld engineer was invaluable. Thanks again to Shaun, welder extraordinaire, who is our listed author for this piece.
The use of coated metals such as galvanized steel has increased over the years in the search for lighter, more durable fabrication solutions. Galvanized means the steel is coated with zinc, usually through either a continuous hot-dip process for sheets, or a literal dip in a zinc bath for smaller and formed parts. Zinc can also be applied through an electroplate process, which gives the metal a thinner but smoother coating. However, the thicker the coating, the more challenging it is to weld.