Systems and methods for welding zinc-coated workpieces

1. A method of forming a weld deposit on a zinc-coated workpiece, comprising:

baking a tubular welding wire by heating the tubular welding wire to between approximately 300° F. and approximately 650° F.,

feeding the tubular welding wire toward a surface of a galvanized workpiece, wherein the tubular welding wire is electrified with pulsed electropositive direct current (DCER), wherein the tubular welding wire is a metal-cored carbon steel or low-alloy steel tubular welding wire in accordance with American Welding Society (AWS) A5.18 or A5.36;

directing a flow of shielding gas toward the surface of the galvanized workpiece near the tubular welding wire, wherein the flow of shielding gas consists essentially of argon (Ar) or a mixture of Ar and carbon dioxide (CO 2 ) that is at least 90% Ar; and

forming the weld deposit on the zinc-coated workpiece using the tubular welding wire while providing the flow of shielding gas near the weld deposit,

wherein the tubular welding wire comprises a granular core disposed inside of a metallic sheath, wherein the granular core comprises:

an organic stabilizer component comprising one or more organic molecules or organic polymers bound to one or more Group I or Group II metals;

a carbon component comprising graphite, graphene, carbon black, lamp black, carbon nanotubes, diamond, or a combination thereof, and

an agglomerate comprising Group I or Group II metal oxides, titanium oxide, and manganese oxides; and

wherein less than approximately 10 wt % of the tubular welding wire is converted to spatter while forming the weld deposit on the zinc-coated workpiece.

2. The method of claim 1 , wherein the weld deposit has a length porosity less than approximately 10% and an area porosity less than approximately 4%.

3. The method of claim 2 , wherein the length porosity is less than approximately 8% and the area porosity is less than approximately 3%.

4. The method of claim 3 , wherein the length porosity is less than approximately 6% and the area porosity is less than approximately 2.5%.

5. The method of claim 4 , wherein the flow of shielding gas consists essentially of Ar, and wherein less than approximately 9 wt % of the tubular welding wire is converted to spatter while forming the weld deposit on the zinc-coated workpiece.

6. The method of claim 5 , wherein less than approximately 8 wt % of the tubular welding wire is converted to spatter while forming the weld deposit on the zinc-coated workpiece.

7. The method of claim 6 , wherein less than approximately 7 wt % of the tubular welding wire is converted to spatter while forming the weld deposit on the zinc-coated workpiece.

8. The method of claim 1 , wherein the flow of shielding gas consists essentially of at least 95% Ar and 5% or less CO 2 .

9. The method of claim 1 , wherein the flow of shielding gas consists essentially of at least 99% Ar and 1% or less CO 2 .

10. The method of claim 1 , wherein the weld deposit has a Charpy-V-Notch toughness greater than approximately 20 ft. lbs. at approximately −20° C. and at approximately −40° C.

11. The method of claim 10 , wherein the Charpy-V-Notch toughness of the weld deposit is at least 30 ft. lbs. at approximately −20° C. and at approximately −40° C.

12. The method of claim 1 , wherein the weld deposit has an ultimate tensile strength (UTS) of at least 70 kilopounds per square inch (kpsi), a yield strength (YS) of at least 70 kpsi, and a percent elongation of at least 18%.

13. The method of claim 1 , wherein the tubular welding wire is the metal-cored carbon steel tubular welding wire in accordance with AWS A5.18 or A5.36.

14. The method of claim 1 , wherein the tubular welding wire is the metal-cored low-alloy steel tubular welding wire in accordance with AWS A5.36.

15. The method of claim 1 , wherein the tubular welding wire comprises a granular core disposed inside of a metallic sheath, wherein the granular core comprises:

one or more filler metals;

one or more alloying components;

one or more carbon components;

one or more alkali metal compound, alkali earth metal compounds, or a combination thereof, and

one or more organic stabilizer components comprising one or more organic molecules or organic polymers bound to one or more Group I or Group II metals.

16. The method of claim 15 , wherein the one or more organic stabilizer components comprise between approximately 0.5% and 1% by weight of the granular core of the tubular welding wire.

17. The method of claim 1 , wherein during baking the tubular welding wire is heated to between approximately 300° F. and approximately 650° F. for up to approximately 6 hours.

18. The method of claim 1 , wherein during baking the tubular welding wire is heated to between approximately 300° F. and approximately 650° F. for between approximately 4 and 6 hours.