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In this video Rob will show you how to weld galvanized steel as well as some precautions. One of the most common ways of making steel resist rust is by combining (alloying) it with a metal that is less likely to corrode: zinc. When steel is submerged in melted zinc, a chemical reaction permanently bonds the zinc to the steel. Therefore, the zinc isn’t exactly a sealer, like paint, because it doesn’t just coat the other metal; it actually permanently becomes a part of it. The most external layer is all zinc, but successive layers are a mixture of zinc and iron, with an interior of pure steel.

This process, known as hot-dipped galvanization, is one of the most common methods of making galvanized steel, but it’s not the only one. Continuous sheet galvanizing runs a steel sheet or wire through molten zinc; it’s also a form of hot-dipping, but leaves a thinner layer of the protective metal. Steel can also be painted or sprayed with zinc, although neither method creates the strong bond that hot-dipping does. Electrogalvanizing or electroplating uses electricity to create the bond between the two metals, which results in relatively thin layer of zinc.

The degree of galvanizing is usually described as the zinc’s weight per surface area rather than its thickness, because this gives a better representation of how much metal has been applied. Steel often gets galvanized after individual parts have been formed, such as braces, nails, screws, beams, or studs. Continuous sheet galvanizing is often done before the metal is used to create products, however, and can withstand some bending and forming without flaking.