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Galvanized - Answer
The stick and MIG process both will not weld galvanized metal. Both of the processes do not allow for the successful expulsion of the vapors created by the zinc coating, thus causing what you describe as “pinholes” and we call porosity. I would recommend you use a gasless process flux cored wire, which has the ability to handle the zinc coating and float it to the surface of the molten weld metal, thus eliminating porosity.
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Upcoming TIG TimeTM Episodes:
Friday, May 1 - TIG Welding Aluminum Foil
At first glance you may be thinking, "Aluminum foil? What relevance does that have?" and to a degree you are correct. On the other hand, this will teach you how to weld at very low amperage as well as test the limits of your machine. TIG on!
Friday, May 10 - TIG Welding 6011 Aluminum Airboat Frames
In this episode you will learn how to weld Aluminum in a few different ways, including thin wall (.120) Aluminum tube, and 1 inch pipe.
Friday, May 17 - Welding at the Indy 500
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