Systems and methods for welding zinc-coated workpieces

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

• feeding a tubular welding wire toward a surface of a galvanized workpiece;
• 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 (CO2) 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;
• and
• wherein the tubular welding wire is electrified with direct current electrode positive (DCEP).