Joining Galvanized and Galvannealed Steels

Automotive anti-corrosion goals are being satisfied with the use of galvanized and galvannealed steels. The trend towards the zinc coated steel usage has necessitated major modifications in joining processes. It is the intent of this paper to describe and discuss how both the Arc and Resistance Spot Welding processes are being modified to successfully join these coated steels in today's automobiles. Zinc coated steels are being production welded with changes in the Gas Metal Arc welding electrode materials (flux core and silicon bronze consumable electrodes) and equipment. Also, changes in Resistance Spot Welding weld schedules and equipment are discussed.