Question:
I am trying to weld a galvanized steel handle to a hardened stainless steel pot and I am doing it with the kind of welder that uses copper wire, oxygen and electricity. What would be the best setting for heat and wire speed? I would prefer smooth, flat welds to bumpy obscure ones.
Answer:
A couple of things strike me as being wrong here.
1- for a wire welder, they do not use copper wire, they use steel, stainless steel, silver solder type wire, and aluminum, plus a few more alloys
2- wire welders do not use compressed oxygen, for most welding they use a mixture of co2 and oxygen or straight gas, usually argon.
Now when welding anything to galvanized, it's best for a clean good weld to grind off the galvanized coating, not completely necessary but best.
To give advise on heat selction and wire speed is impossible without actually trying the particular machine and metal thickness being welded.
Best advise I can give is trial and error. Get some scrap of the same material and keep trying until you're satisfied with the results.
Once you weld the galvanized handle to the pot, even with stainless wire, it will still be subject to rust on the weld.
It is also possible that if you're using one of those home units that use 120 volts, it might not give enough heat to weld heavy stainless.
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