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Copper in Welding Wire causing E Coat problems

Copper in Welding Wire causing E Coat problems

(OP)
During welding of a steel assembly, copper is deposited on the surface of the weld.  This area will not E Coat and requires mechanical removal of the deposit.  Different ways of chemically removing the copper has failed.  Please suggest either a new wire composition that will eliminate the copper deposits or something to add to the chemical pre-treat that will sufficiently remove the copper before E Coat.

RE: Copper in Welding Wire causing E Coat problems

This is a well-known problem in the automotive industry.  Either the weld must be mechanically abraded (media blasted, wire wheel/brush, etc.) or it will have to be acid pickled.  Acid cleaning, meaning low concentration of acid, is not sufficient, it must be pickled in concentrated acid in order to remove the surface layer.

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