Current Required for Welding ERW Pipes

Probably. Where have you looked, so far.

Anywhere? Please list the sources you have checked.

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No, there isn't really any such formula. You probably don't want to weld GI pipe, anyway, on account of zinc fumes.

Don't weld galvanised anything. Galvanised pipe is intended to be screwed together. Welding galvinised anything produces zinc-rich fumes that are a health hazard for the individuals nearby. In the case of pipe, any protection that the zinc coating offers for the rest of the pipe material on the inside will be lost in the region of the weld, negating the reason for using galvanised pipe in the first place.

Just don't do it.

There are plenty of other materials for all sorts of process fluids that might otherwise go in galvanised pipe.

I take it you don't know much about welding.

Yes the formula is you look at the welding rods amp rating VS its recommended range of thickness of metal it should be used with then set your welder to somewhere in that range.

As far as welding galvanized metal I and millions of others do it all the time. The only trick is to grind off the coating where you need to weld then do the welding in an open well ventilated area.

The 'secret' 50 years ago for the safe welding of galvanised material was to drink plenty of milk. I have no idea of the scientific basis for that but it worked for me -- I think.

As far as the best current to use goes, surely it is a matter of empiricism. It certainly was back then.

When I were a lad I was up on a shed roof brazing some galvy grain ducting. Took severe stomach cramps and couldn't get down the ladder for a couple of hours. Talk about learning the hard way!!