Heavy Gage Wire Welding

I am a retired DYI type but nothing I've done in the past has had anything to do with welding. My project now is to make figures out of heavy gauge wire for the holidays using the wire that was suppose to be used to attach the chain link to the post. I think this is about 8 gauge galvanized and I would like to be able to weld the wire together for stability and longevity before I paint it so first I need to know if I can weld this stuff then I will need to know how I would go about it with as little expense as possible.

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Sep 20, 2013
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Been there
by: Goldtrigger

All comments above are reasonable accurate. Wire feed with flux core minimum heat will work. Clean with flap wheel, grinder, or wire brush at the weld point as much as possible.

Can't stress enough about ventilation. Fan or open air.

Some have said drink milk after welding to calm the stomach. Never had a problem with that, but have heard it around the shop when welding galvanized tanks.

Jul 01, 2013
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neat idea!
by: Norther Arc Stainless.

Like the other helpful comments posted. Try to clean of as much of the galvanized coating as you can I would clean it with a softer abrasive such as a scotch bright wheel, Because it is such a thin material you want to avoid thinning it out even more. I would also use a flux core wire feeder welder with as minimal heat as possible.

Mar 15, 2013
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Galvanizing DOES NOT contain Phosgene Gas
by: Anonymous

OK, lots of info here. First, galvanizing DOES NOT contain Phosgene gas. Freon. Second, Zinc,while not desirable to inhale, is not "Highly Toxic", as a matter of fact,your body requires trace amounts of zinc. In high quantities,such as welding galvanized for years,thus causing long term exposure,it is damaging. I have had to weld galvanized a lot over the years,the best way IMHO is to buff the weld location with a wire wheel, then use a Mig welder with a Flux core wire suitable for mild steel such as Innershield from Lincoln. Use a fan or evacuator if you have one,to remove the zinc fumes and have your weld area as open as possible. The flux core will keep the galvanized from contaminating the weld,that's what it's for.
Use a good brand of wire,avoid the Harbor Freight stuff unless it specifically states "Barrium Free" on the box or wrapper. Good luck,
Jim Sites
Sites Welding Service
Leander, Texas 78641

Dec 02, 2011
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dyi man
by: Jim

For the do it yourselfer..........any welding via fire will greatly diminish the strength of the metal. Plus the great build up of heat on your project. Do use a 110 volt mig ! Very little grinding is needed to expose raw metal as the electro plating is extremely thin. As far as the fumes go, yes, they are nasty. But......useing a fan to blow away the fumes will blow away the argon also. I assume you will be doing bench work, maybe piece by piece? If so, then all that is needed is a small fan blowing gently. I have learned over the years that if I just relax, hold my breath momentarily to do one tack weld at a time, stop welding, lean back and look at my work, exhale, then I can do a real nice job. I will also assume again that all that is needed is small welds anyhow. As with any welding I would strongly suggest that you do a practice weld or two with the same material before you tackle the actual job. Always remember.......no question is a dumb question.

Nov 04, 2011
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Poison
by: Sal

Your wire can be welded but the galvanising needs to be removed as much as possible. You can burn it off or grind it off. Be sure you have good ventalation. A fan, or outside with a breeze. and then you need to paint it. It is safer if you crimp it or clamp it.

Sep 09, 2011
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welding galvanized metal
by: snobirdfred

yes you canweld galvanized do not repeat do not breath in fumes they contain fosgene enough will kill you just simple brazing would be easier if you do weld you might notice a strange white or yellow substance appearing at edge of the weld this basicly is phosphorus be warned this stuff can be dangerous

Jul 22, 2011
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Chain
by: jm welding

Yes you can weld it. Like mentioned before don't breathe those fumes. turn on a fan on even wear a respirator. Depending on the chain size a little 110v welder with some innershield wire(wire that doesn't require gas) should work. Hope this helps.

Jun 05, 2011
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wire
by: k and m welding

i believe the wire used to hold the fence to the poles is aluminum the fencing it self is galv coated

May 08, 2011
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Welding galvenized metal!
by: Don S.

If you would grind off the Galvenized coating at the weld point it would be possible to wire weld it at that point. Galvenizing has to be removed to faciliate welding.

Mar 28, 2011
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Galvanized wire
by: Doug Wendell

Welding galvanized wire has all the problems your other responses indicate. Soldering also has its problems. Therefore, I would try what amounts to a brazing process.

A company called Aladdin Welding Products makes a brazing rod called Aladdin 3 in 1, which works great on galvanized (it's the only thing I have ever found that does)-- website is Aladdin3in1.com. It requires no flux, and flows at about 750 degrees F, so you can use it with a propane torch, or a "Presto-lite" type acetylene - air torch. You will be working with fairly thin wire so a regular plumbers propane torch will probably work. (I have found the most covenient type to be one with a hose to provice more flexibility in how you use it, (roughly $35 to $40 at Home Depot or lots of other places.)

The 3 in 1 rod comes in 18" sticks from 1/16th inch up to about 1/4" in dia. For what you are doing I would buy the one or two sizes smaller than the galvanized wire you are using -- two sizes smaller if you are only joining two or three pieces of wire, only one size smaller if you are joining more than three pieces. As with all brazing work, getting everything thoroughly clean before you braze is essential. I would clean the wire with steel wool, and clean the 3 in 1 rod with steel wool also, then wipe both of them off with acetone on a rag.

BEFORE YOU START WORK, MOVE THE RAG AND THE ACETONE FAR AWAY FROM THE AREA WHERE YOU ARE GOING TO USE THE TORCH, THE STUFF IS HIGHLY FLAMMABLE. ALSO, IF YOU START SEEING WHITE FUMES COMMING OFF THE WIRE WHILE YOU ARE WORKING, IT MEANS YOU HAVE HEATED THE WIRE TOO MUCH. BACK AWAY FROM THE FUMES (TOXIC), AND LET THINGS COOL. COOL.ET AWAY FR

Aladdin has a $50 or $100 minimum order, and they want you to pay through "Pay Pal" with your credit card. I would think a 1# tube of two sizes -- probably 1/16" and 3/32", and a 1 # assortment tube would add up to about that.

I really like the Alladin 3 in 1 rod, but I'm sure there are products similar to it, I just don't know their names. Perhaps others in the McWelding family can provide their names and where to get them.

I hope this helps

Mar 28, 2011
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wire welding
by: blumoon

If at all possible, don't use galvenised wire, I do some small welding with wire and small ga. metal and gal. is a pain to get clean to make a very good weld, besides the fumes will kill you. Use a small 110v wire feed welder, and practice you can get to where you can weld horse shoe nails together with ease, good luck

Mar 25, 2011
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23 YRS EXP/
by: A WESTERN WELDING

for one, galvanize is a coating process, which of coarse is high toxic, one you dont want to use a straight wire/ argon method, because the galv/ when welding will mix with your argon gas contaminating the weld. if you use a mig welder you want to use a flux core wire , this will elimanate a contaminting mix,035 wire will be suitable for any process up to 1/4 if you have proper amp/60 series stick rod ic a good choice, but remember ,all 60 srs rods do not have a tencil streanght,what that means if you have an item that will bend in any direction on that weld it will breAK, WE CAll them 60 rods fast frezz because they will burn through rust and mend like steel.any material that has a tensil or yeild should use a 70 s series rod A WESTERN WELDING DAYTONA BEACH FL 386 322-1851

Mar 25, 2011
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galvanized welding.
by: Anonymous

Buy a little 100 dollar welder. wirefeed of course ! Yes you can weld galvanized . Try not to breath in the smoke.

Mar 25, 2011
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Galvanized
by: EPJohnso

I wouldn't weld galvanized, unless it was repair of something, and then only in the open, and a breese either natural or a fan. The Zinc is exceptionally toxic!

Mar 25, 2011
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welding galvanize
by: Pat

After cleaning use 6011 stick rod for best results

Mar 25, 2011
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heavy gage wire welding
by: Rikasso

Hello
Your project sounds like fun.
First thing you need to know about galvenized metal is that the fumes are DEADLY!!!!!!.
It's best to try and clean the galv of where you want to weld it, and then just trial & error for heat, and wire feed

REMEMBER THE FUMES ARE DEADLY!!!!!!!!

Hope this helps.
www.rikasso.com is my web site take a look if you like.

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