I know the manuals say you can’t TIG weld zinc (we are talking 99% pure zinc, folks, not galvanized steel…). However, seeing as other shops are indicating they are TIG welding these zinc counter tops, etc., we tried it with .062 thick zink sheet. We used strips of zinc cut out of the actual zinc sheet for filler rod. We set the machine at around 98-100 (AC) amps and it worked great. This material has such a low melting point, when you TIG weld it, it gets molten to a point where it is ready for the filler rod before it gets hot enough to create the white smoke, i.e. fumes. It behaves a bit like TIG welding aluminum. However, if you do let it get too hot, to a point where it turns a pinkish color, then it will create smoke/fumes, but at that point you have gotten it too hot to work with anyway. Any good TIG welder can control this with paying attention and by control with the foot pedal.

We also tried soldering and it worked very well also. Both methods produced a satisfactory joint that finished out nicely, though the soldered joint was a slightly different color. Since we used zinc for the filler rod, the TIG welded joint was a perfect match! And again, neither method produced any bad fumes.

Though there are some particulars to consider with installation of a zinc counter top, but as is so with copper or any other “exotic” metal. One thing about the zinc, as with copper, is that the surface is naturally anti-bacterial and is perfectly safe and code compliant with regards to coming in contact with the zinc surface.

It also appears that you can gas weld zinc and that is the next thing on our list to try. We will post another reply here as soon as we try that procedure.

I will be posting an information page on care, maintancen, etc., regarding zinc counter tops on our website today. Feel free to take a look.