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What are the most common issues with rust at weld points and how are they mitigated?
Rust at weld points is a prevalent issue in metal fabrication, often leading to structural weaknesses and premature failure. The most common problems include galvanic corrosion due to dissimilar metals, crevice corrosion in poorly sealed joints, and oxidation from inadequate surface preparation. Moisture, salt exposure, and chemical contaminants accelerate these issues.
To mitigate rust, proper surface cleaning before welding is critical. Techniques like grinding, sandblasting, or chemical treatments remove oxidation and contaminants. Applying protective coatings, such as zinc-rich primers or epoxy paints, creates a barrier against moisture. Using compatible metals and corrosion-resistant filler materials reduces galvanic corrosion risks.
Post-weld treatments like passivation for stainless steel or anodizing for aluminum enhance resistance. Regular inspections and maintenance, including touch-up coatings, prolong weld life. Implementing these strategies ensures durable, rust-free welds in harsh environments.
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