How to Weld Galvanizing Kettle

A. The preferred rod is a E-6012. Its an old standard but works the best. What ever rod you use make sure it has the lowest possible silicon content. The water problem could be coming from the products of combustion or condensation from within the combustion space surrounding the pot.

A. The type of welding electrode is extremely important. Most kettle steel will have silicon content of .005 or less. The rod needs to be close to that. Strength of rod is not a real factor, as most any rod will be strong enough. The water seepage problem is probably from the condensing water that is vaporized during the process of burning with fuel. It can be probably be corrected by properly adjusting burners and/or changing flue or furnace design.

A. Why don't try SILOX FE of Ador. This electrode is mainly for zinc pot welding.

A. My opinion about kettle failure is: don't try to make it yourself, Get it from a specialized kettle manufacturer only.
They are very few, but you may search in India, Germany, and Australia for zinc pot experts.

A. Arc welder.

But ensure you get the right electrodes, must be very low Si level, or the weld will dissolve in the zinc, leaving a big mess !

A. Sir:
The two companies that I know who make galvanizing kettles are Pilling (Germany) and Columbiana (USA). You should find out from these companies (or the company that you purchased your kettle) the correct welding rod and the methods for welding. After welding them x-ray the welds to make sure that they are good. Check the "heat" (chemical composition) of your kettle iron to make sure it is proper. I think Columbiana uses "normal" welding methods whereas I think Pilling may use a "slag welding" method, whatever that may be.

Regards,

A. SAE/AISI 1006.

Welding consumable must put down weld metal which has either (a) less than 0.05% silicon, or (b) between 0.11 and 0.25% silicon. It must not be between 0.05 and 0.11

A. Sir:
35 years ago there was a steel (iron product) that was called "max ten." This meant that with the exclusion of iron the other ingredients all added together totaled 0.10%. Thus the carbon, silicon, phosphorus, manganese, etc. all added together could not exceed 0.10%. Another terminology was "fire-box steel." Still another terminology was Armco Iron (or steel). The usual thickness of steel (iron) kettles is 2 inches in North America and welded with very specific welding rod. The welds are normally x-rayed to be sure that they are good. Making a galvanizing kettle is NOT a "do it yourself" job.
[name deleted by editor ( huh? why?)] in the USA and [name deleted by editor ( huh? why?)] in Germany are major suppliers of hot dip galvanizing kettles. Through the heating zone on the sidewalls (excluding the top 6 inches and the bottom 9 to 12 inches which are insulated) it is allowed to transmit 10,000 Btu's/sq ft/hour with an expected kettle life of 10 years. High-velocity end-firing is the most efficient system with proper shielding near the burners. Looking from above the hot gases circle the kettle. The burners are on diagonal corners with initial firing along the long sides. The depth(numerator) to width(denominator) ratio should be about 1.5 to 2. E.G. considerably deeper than wide. I have published several articles in the journal METAL FINISHING which details these informations.
I strongly recommend that you purchase a commercially made kettle and contract a qualified kettle furnace installer.
Regards,

A. Sir:
A galvanizer told me recently that the proper welding rod is "FLEET 7." He also said that MIG equipment is better. The rod, or wire only has traces of silicon and phosphorus (also I think that low aluminum is important).
Regards,

A. The steel used for galvanising pots should conform to BS 2858. Also the higher the temperature of the zinc the more the dissolving effects.
There are new zinc alloys available and new methods of maintaining the alloying elements in solution. These factors together can greatly reduce zinc consumption.

Thank you so much Ted.

Q. If someone help to share "Welding Procedure of Galvanizing Kettle" please?

A. It is quite possible to repair a kettle by welding. many have successfully done this.
It is most common and most successful to make the whole repair in weld, not to put plates in.
The weld rod needs to be much lower than 2%Si that you mention. It needs to be almost zero. Most describe the Si content as "trace".

A. It's Possible to weld Galvanizing kettle and make plate thickness as desired.
You have to select Proper Welding Electrodes to repair your kettle.