Aluminum to Galvanized Steel?
RSS | Subscribe | Contact Us | Advertise | About Us
Results 1 to 16 of 16
  1. #1
    Join Date
    Jul 2006
    Location
    MSP
    Posts
    70

    Aluminum to Galvanized Steel?

    I am looking for a solution to joining Aluminum to Galvanized Steel. Whether it be welding, brazing, explosion cladding, friction stir welding, thermal spraying. Each piece would be 2MM thick and needs to withstand thermal shock from -40 to 120 degree Fahrenheit. If money were no object how would you suggest joining these two metals. I know a major problem with these two metals is the galvanic corrosion that takes place between them but are there any other major issues besides dissimilar melting tempuratures? Any suggestions would be great.

  2. #2
    Join Date
    Jan 2008
    Location
    Fond du Lac, Wi
    Posts
    965

    Re: Aluminum to Galvanized Steel?

    Elastic urethane adhesive? Perhaps with mechanical fastening as well? The CoE for those materials are so different it may cause more issues than corrosion initially.

  3. #3
    Join Date
    Feb 2006
    Location
    Back in HB, close to my boys!!
    Posts
    4,689

    Re: Aluminum to Galvanized Steel?

    Epoxies can work if there is sufficient mating surface and overlap, ie sleeve to put one into another. The other option is mechanically fasten; good old nuts and bolts or rivets.
    And then, after so much work...... you have it in your hand, and you look over to your side...... and the runner has run off. Leaving you holding the prize, wondering when the runner will return.

  4. #4
    Join Date
    Jan 2007
    Location
    UK
    Posts
    670

    Re: Aluminum to Galvanized Steel?

    http://www.aws.org/w/a/wj/2005/06/038/index.html



    Other manufacturers may give the process a different name, EWM for example call it 'coldarc'. You did say money was no object

  5. #5
    Join Date
    Mar 2007
    Location
    Deltaville, VA
    Posts
    2,901

    Re: Aluminum to Galvanized Steel?

    As Rojo mentioned:

    Bolts, Nuts, and Washers
    Syncro 250 DX
    Dynasty 200 DX
    MM 251 w/30A SG
    XMT 304 w/714 Feeder & Optima Pulser
    HH187
    Dialarc 250 AC/DC
    Hypertherm PM 1250
    Smith, Harris, Victor O/A
    Smith and Thermco Gas Mixers
    Access to a full fab shop with CNC Plasma, Water Jet, etc.

  6. #6
    Join Date
    Oct 2007
    Location
    Yuba City, CA
    Posts
    1,631

    First step is to question the designer

    Quote Originally Posted by TiFreak View Post
    I am looking for a solution to joining Aluminum to Galvanized Steel. Whether it be welding, brazing, explosion cladding, friction stir welding, thermal spraying. Each piece would be 2MM thick and needs to withstand thermal shock from -40 to 120 degree Fahrenheit. If money were no object how would you suggest joining these two metals. I know a major problem with these two metals is the galvanic corrosion that takes place between them but are there any other major issues besides dissimilar melting tempuratures? Any suggestions would be great.
    This is a great example of the need to question the designer, when they've specified
    something that is impossible, close to impossible or at the minimum--wholly unpractical.

    For all you & we know, the designer obviously didn't give this any thought, he/she
    just specified 'weld it'........without having any clues as to what's involved.

    (Those who create problems with their ideas, as opposed to solving/anticipating/finding
    solutions---are neither designers or engineers......simply ignorant wannabees )
    Blackbird

  7. #7
    Join Date
    Mar 2009
    Location
    Chicago, IL
    Posts
    12

    Re: Aluminum to Galvanized Steel?

    I've used explosion bonded strips in the past. VERY effective!

    Here's a European company that makes them, although sometimes it is hard to find.
    http://www.triplate.com/?pagina=triplate_solution
    http://www.smt-holland.com/
    A pic from their website

    Last edited by Al Bundy; 09-11-2009 at 11:10 PM.

  8. #8
    Join Date
    Jul 2008
    Posts
    109

    Re: Aluminum to Galvanized Steel?

    Silver solder using OAW. Try to obtain a grade that melts below the melting point of the aluminium,

    GTAW and copper lithium filler might work also on DCEN. You need to work this though to obtain good fusion.

    In both cases, strip the galv off first.

    Good luck.

  9. #9
    Join Date
    May 2006
    Location
    Augusta, GA
    Posts
    207

    Re: Aluminum to Galvanized Steel?

    TeddCo
    HTP Microcut 400 & Invertig 160DC
    Smith Dual Guard MD-510 OA Rig
    Lincoln SP135+
    Hobart Stickmate LX 235/160

  10. #10

    Re: Aluminum to Galvanized Steel?

    Quote Originally Posted by TiFreak View Post
    I am looking for a solution to joining Aluminum to Galvanized Steel. Whether it be welding, brazing, explosion cladding, friction stir welding, thermal spraying. Each piece would be 2MM thick and needs to withstand thermal shock from -40 to 120 degree Fahrenheit. If money were no object how would you suggest joining these two metals. I know a major problem with these two metals is the galvanic corrosion that takes place between them but are there any other major issues besides dissimilar melting tempuratures? Any suggestions would be great.
    I also really want to know the best suitable electrode to weld galvanized steel with aluminium

  11. #11
    Join Date
    Jan 2006
    Location
    In A Nice Comfy Chair
    Posts
    17,832

    Re: Aluminum to Galvanized Steel?

    Quote Originally Posted by dechiben View Post
    I also really want to know the best suitable electrode to weld galvanized steel with aluminium
    Does NOT Exist.

    ...zap!


    I am not completely insane..
    Some parts are missing

    Professional Driver on a closed course....
    Do not attempt.

  12. #12
    Join Date
    Dec 2015
    Location
    Western New York State, USA
    Posts
    1,000

    Re: Aluminum to Galvanized Steel?

    Quote Originally Posted by zapster View Post
    Does NOT Exist.

    ...zap!
    .
    .
    i have seen various products that will join just about anything but more likely closer to being a solder or brazing rod not technically a welding rod. never say never and do not be surprised if it is very expensive per pound. and i have no ideal how strong or duable like shock resistance and corrosion resistant it is
    .
    http://muggyweld.com/super-alloy-1
    .
    this company sells tig filler metal for aluminum to steel
    .
    http://alumasteeltigrod.com/

  13. #13
    Join Date
    Sep 2014
    Posts
    181

    Re: Aluminum to Galvanized Steel?

    there is no welding rod period that works on aluminum to steel. You can solder, mechanically fasten it or use explosion or friction stir welding.

  14. #14
    Join Date
    Sep 2014
    Posts
    181

    Re: Aluminum to Galvanized Steel?

    that welding rod also says it's low strength.

  15. #15
    Join Date
    Dec 2015
    Location
    Western New York State, USA
    Posts
    1,000

    Re: Aluminum to Galvanized Steel?

    Quote Originally Posted by iongar View Post
    there is no welding rod period that works on aluminum to steel. You can solder, mechanically fasten it or use explosion or friction stir welding.
    .
    there is no "welding rod" that is a alloy of aluminum and steel. it is a solder or brazing rod that often can be tig welded so it acts more like everdur or silicon bronze filler. you do not melt the aluminum or steel only get hot enough for the filler to flow and stick. none the less it often can be applied with tig
    .
    some alloys are like $50 or $100/lb and outside in rain and salt the corrosion ability might be very limited. Intergranular stress corrosion i have seen with steel handrail and certain chemicals. after many years a weld can get brittle where a good yank on handrail and the weld breaks off. when originally welded it was 10x stronger. literally the chemicals attack the weld by soaking into metal and effecting metal deep inside the weld. just saying any joining methods needs long term testing if anybody will care if joint fails
    .
    also some alloys are zinc or tin or cadmium based. obviously cadmium was popular many years ago before its toxic effects were appreciated.

  16. #16
    Join Date
    Jan 2008
    Location
    Richmond, Virginia
    Posts
    6,012

    Re: Aluminum to Galvanized Steel?

    "USMCPOP" First-born son: KIA Iraq 1/26/05
    Syncrowave 250 w/ Coolmate 3
    Dialarc 250, Idealarc 250
    SP-175 +
    TA 161 STL
    Lincwelder AC180C (1952)
    Victor & Smith O/A torches
    Miller spot welder

Posting Permissions

  • You may not post new threads
  • You may not post replies
  • You may not post attachments
  • You may not edit your posts
  •  
RSS | Home | Penton Media | Contact Us | Subscribe | For Advertisers | Terms of Use | Privacy Statement