Welding Zinc To Steel. This results from the variation in boiling points between zinc lower and steel. In order to weld zinc coated steels in lap joint configuration a gap with 01 mm-02mm thick is usually required which provides a passage for a highly-pressurized zinc vapor to escape.
Resistance welding solid zinc is done with currents that are equivalent to low electrode forces and steel. In addition the residuals left after welding on the surface of the. You may also want to remove it at least 2 inches on either side of the weld joint to be safe.
Cavities and internal defects can easily be seen but can be diminished with the help of a forging force.
I assume it was the zinc vaporizing before the other stuff AlMgCu was even halfway to their melting point. However welding coated steels has always been a critical issue with conventional processes and consumables. The effect of this in practice is that when welders start work on these materials the zinc is vaporized and becomes trapped in the steels. On these and other subjects detailed hereafter some.