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Old 01-03-2011, 02:46 AM   #1
biggreen96
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Default Aluminized tubing welds are not nice looking.

I just did the exhaust for my rally project and used plain aluminized from the exhaust shop. I tig'd it since that is what I have, took forever... but no matter what I tried I couldn't get nice (looking) welds. Penetration is fine, I'm not worried about it coming apart, but I am glad it's under the car where it's hidden!

Is there a trick to aluminized?
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Old 01-03-2011, 11:20 AM   #2
icky
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Grind off aluminized coating and weld like it was plain mild steel.
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Old 01-03-2011, 12:58 PM   #3
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What he said. Also be aware that many exhaust shops use galvanized which when welded can emit very hazardous (zinc oxide) fumes. Use caution!
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Old 01-03-2011, 08:17 PM   #4
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Quote:
Originally Posted by Surb00 View Post
What he said. Also be aware that many exhaust shops use galvanized which when welded can emit very hazardous (zinc oxide) fumes. Use caution!
The Zinc Oxide is not what is dangerous for you. It's the phosgene gas that's created when the Zinc is burned that'll get you. If you are in fact welding on zinc coated material grind or sand it off until the metal starts creating sparks. If you've not reached the sparking point, you are not through the Zinc. If you feel sick after inhaling said phosgene gas, drink milk. You will know when you are creating this gas when the burned zinc turns to a white/yellowish powder. Hope this helps.
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Old 01-03-2011, 08:32 PM   #5
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Oh my. Well I certainly didn't get all the coating off, since I just hit it real quick with a wire wheel. And many of the welds were bordered in a yellowish marking. No wonder I've been feeling off. I drink milk like it was going out of style so I had that going for me...

Thanks for the replies guys, hopefully this gets seen by people and they can avoid my mistakes.
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Old 01-05-2011, 01:59 AM   #6
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Old 01-05-2011, 03:47 AM   #7
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FYI: Phosgene was probably the most lethal chemical weapon used in WWI. The only problem was it generally took about a day before people exposed to it died.
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Old 01-05-2011, 03:52 AM   #8
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Just so everyone knows I'm still here(alive). I did feel off for the few days I was working on the exhaust in the evenings. Perhaps it was the metal fever described in the OSHA link. That first link I had come across a while ago so I am aware of the dangers of phosgene. But I didnt burn any chlorinated chemicals so I'm safe in that front.

Last edited by biggreen96; 01-05-2011 at 04:04 AM.
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Old 01-05-2011, 04:23 AM   #9
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I've welded galvanized stuff before too, it's nasty. The one thing I do like about tig welding is ozone. I think it smells like cucumbers. Plus it's good for the environment.

I'm saving the ozone layer one bead at a time.
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Old 01-11-2011, 05:51 PM   #10
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Sorry to pull up an old thread, but 1. How are the OP's welds holding up? 2. Ozone is very bad to inhale and ground level ozone (a major component of smog) is bad for the environment

Also, I'm not a pro welder and have no more than a few learning experiences in welding, but I believe that no weld would hold that good over a plating, welding the base metal would certainly be best. But I'm not a welder, so what do I know?

Last edited by P4radigm; 01-11-2011 at 05:59 PM.
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Old 01-11-2011, 06:01 PM   #11
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The welds have not been tested yet, as the car is still under construction, but for a little test I installed the system on the car and then I hung from it to test the hangers. It held up to my 165 pounds lol. I got plenty of penetration so I imagine they will be fine.
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Old 01-20-2011, 04:49 AM   #12
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Don't breathe the ozone, it's a free radical and does cell damage.

Also the ozone you create here doesn't reach the ozone layer, it just causes health problems.
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Old 01-20-2011, 07:12 AM   #13
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^^^ But it smells like cucumbers....how can that be bad!?!?!?


Jay
doesn't like to sniff any welding fumes
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Old 02-20-2011, 06:17 PM   #14
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and it tastes like chicken...
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Old 02-25-2011, 12:33 PM   #15
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Pretty sure I had Metal Fume Fever 2 or 3 weeks back (I had several of the signs of it). I didn't even weld any of the galvy that was being worked on, but I was still in the shop doing other things the few days it was being welded, whole place was full of smoke from it.

Fever lasted from Friday till Sunday night, got up to 102.3.
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Old 02-26-2011, 08:39 AM   #16
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Quote:
Originally Posted by XplicitRacingDesign View Post
Pretty sure I had Metal Fume Fever 2 or 3 weeks back (I had several of the signs of it). I didn't even weld any of the galvy that was being worked on, but I was still in the shop doing other things the few days it was being welded, whole place was full of smoke from it.

Fever lasted from Friday till Sunday night, got up to 102.3.
if your around this stuff, drink lots of milk.

I was taught why in high school ( took 4 years of welding) but don't remember. Guys that weld on galvanized usually wear masks of some sort but also drink lots of milk to help out.
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Old 02-26-2011, 06:11 PM   #17
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another source of phosgene is if you are using a chlorinated brake cleaner to clean the metal. exposure to the light in the arc will create phosgene. brake cleaners have moved away from being chlorinated but you should read the can before using for weld prep.
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Old 02-28-2011, 02:06 PM   #18
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Quote:
Originally Posted by WeldingHank

if your around this stuff, drink lots of milk.

I was taught why in high school ( took 4 years of welding) but don't remember. Guys that weld on galvanized usually wear masks of some sort but also drink lots of milk to help out.
Yeah, the calcium in the milk is supposed to help prevent your body from absorbing it.

We usually don't do much welding on stuff that's already galvanized, and where I wasn't welding wear a mask, I was busy doing something else and really didn't even think about it... guess I know better now.
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Old 03-07-2011, 11:26 PM   #19
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Quote:
Originally Posted by biggreen96 View Post
I just did the exhaust for my rally project and used plain aluminized from the exhaust shop. I tig'd it since that is what I have, took forever... but no matter what I tried I couldn't get nice (looking) welds. Penetration is fine, I'm not worried about it coming apart, but I am glad it's under the car where it's hidden!

Is there a trick to aluminized?
1. Dont be a cheap. If you want it to look good, at least go stainless, And if you want to tig aluminized steel, your wasting your time, just mig the ****, thats what aluminized steel is.

Its not cheap to be cool!!
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Old 03-08-2011, 03:45 PM   #20
biggreen96
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Well even though I made the thread complaining about the bad looking welds, the looks are not my concern. It's an exhaust for a rally car. (Driven by a novice rally racer, me) It's going to get f'd up. Looks are way way down on the list.
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Old 06-17-2011, 11:46 AM   #21
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i had metal fume fever a few weeks ago. it lasted about a week and a half and is an experience i never want to repeat. i was drinking whole milk at a rate of a gallon a day afterwards. i had welded galvy before with no problems. this time i guess it caught up to me. it doesnt take much galvy to make you sick, so please be careful, as MFF is no joke.
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