can you put galvanized and stainless steel together
Table of Contents
Introduction
Mixing galvanized steel and stainless steel in a project is something a lot of people wonder about. Can you just bolt them together or weld them, and what problems might pop up? This blog is here to break it down into simple English, no jargon, so you can understand what works, what doesn’t, and how to do it right
Why the Question Even Matters
Galvanized steel is regular steel with a zinc coating, which helps prevent rust. Stainless steel, on the other hand, has a lot of chromium (and sometimes nickel or molybdenum), and it resists rust on its own.
When these two materials come in contact, especially in wet or humid environments, a chemical reaction can happen. This reaction is called galvanic corrosion, and it happens when two different metals touch in the presence of an electrolyte, like water or salt. The zinc or iron in the galvanized steel starts to corrode faster because it becomes the “sacrificial” metal, protecting the stainless steel at its own expense.
What You Need to Know
1. Understanding Galvanic Corrosion
If galvanized steel touches stainless steel and water is around, the zinc will corrode first.
This corrosion can wear away the zinc layer, exposing the steel beneath.
You’ll end up with rust spots and weak spots on the galvanized, even though the stainless steel stays clean.
2. The Strength of Stainless Steel
Stainless steel won’t rust easily on its own.
It keeps looking nice and stays strong over time.
Even if the galvanized rusts, the stainless steel will still hold up.
When Is It Okay to Mix Them?
Yes, you can put galvanized and stainless steel together — but only if you do it right. Here are some ways to make it work:
A. Use a Barrier
- Put paint, epoxy, or rubber between them.
- This keeps them from touching directly, stopping the chemical reaction.
- Make sure the coating is thick and covers all parts.
B. Use Separators
- Plastic washers, gaskets, or sleeves can go between bolts or screws.
- These keep the metals from touching even if water gets in.
- It’s simple but effective.
C. Opt for a Less Reactive Galvanized
- There are different types of zinc coatings.
- Use one that dries and seals well, so it doesn’t leach zinc into stainless steel.
- This reduces the corrosion risk.
D. Avoid Wet Environments
- If you can keep the area dry, problems lessen.
- Indoors or sheltered places are better than places with lots of rain or humidity.
Real-World Examples
i. Frames Made From Stainless Steel Extrusion Profiles
Let’s say you’re building a workstation frame using stainless steel extrusion profiles. You want to attach some panels made from galvanized sheets. Here's what to do:
- Clean both surfaces so they fit well.
- Apply a layer of paint or primer where they’ll touch.
- Use washers or gaskets under all screws.
- Seal edges with silicone or rubber tape.
This stops moisture from causing corrosion, keeps everything sturdy, and gives you a clean look.
ii. Exhaust Systems With a 2 1/2 Flex Exhaust Pipe
If you’re working on a car exhaust with a 2 1/2 flex exhaust pipe in stainless and want to join a galvanized bracket or hanger:
- Wrap the bracket ends with heat-safe rubber or silicone wrap.
- Or, use stainless clamps around galvanized parts so they don’t touch directly.
- This way, even with heat and moisture, the stainless part stays pristine, and the galvanized part doesn’t corrode fast.
iii. Structural Work Using Stainless Hex Bar
Let’s say you're building a gate or railing with a stainless hex bar as a decorative element and galvanized support posts:
- Clean all contact surfaces.
- Paint or coat the end of the hex bar where it meets the galvanized post.
- Use plastic or nylon spacers between them.
- Apply silicone sealant around the joint to block water.
This prevents direct contact and keeps everything corrosion-resistant.
What to Expect If You Don’t Take Care
If galvanic corrosion happens without protection, here’s what can go wrong:
- Rust spots appear on the galvanized material.
- The connection weakens over time.
- Moisture gets trapped, making corrosion worse.
- You may need to redo or replace parts far sooner than expected.
How to Do It Right: Step by Step Guide
Here’s a quick clear guide you can follow when mixing galvanized and stainless steel:
- Clean everything – remove dirt and oil.
- Paint or coat both surfaces that will touch.
- Use plastic or rubber spacers between metals.
- Seal edges and joints with silicone.
- Check occasionally for signs of wear or rust.
These steps take a little time but save a lot of hassle down the road.
FAQs
Q: Can you weld galvanized to stainless steel?
- No, welding these together is a bad idea. The zinc makes lots of toxic fumes, the weld is weak, and corrosion is likely. Better to bolt them in with barriers.
Q: What if you have to use bolts?
- Use stainless hardware.
- Put plastic washers or sleeves under nuts and heads.
- Wrap or coat the bolt area as well.
Q: What environments are okay?
- Indoor, dry locations are safest.
- Outdoor areas with rain or salt air need protection and coating.
Wrapping Up
Mixing galvanized steel and stainless steel is doable, but you can’t just slap them together. To keep things lasting and nice-looking, always:
- Clean and coat contact surfaces.
- Use plastic or rubber barriers.
- Seal edges to keep moisture out.
Whether you're working with stainless steel extrusion profiles, a 2 1/2 flex exhaust pipe, or a stainless hex bar, using these tricks keeps your project strong and rust-free.
Final Thoughts
Taking the time to separate these metals properly isn’t extra work—it’s smart planning. The upfront effort saves you from rust, wobbly parts, and future repairs. And when you see your creation lasting years in great shape, you’ll know it was worth it.