Help! We are welding a length of 1020 steel 3/8 X 3/4 inch thick to a piece of rectangular tubing 1" X 2" x 1/8" wall using the GMAW process. The process parameters are 22 Volts , 160 Amps 95% Argon 5 % Oxygen shielding gas and trying to get a 4 mm fillet weld. This part then goes out to be plated with Zink Di-chromate. We are seeing cracks "underbead" and "root" in our cut and etch samples. Where can I find information on the relationships between cracking and plating of welded assemblies???? Thanx to all! Tim Tompkins TTompkins@Searsseating.com or Timmmt@Hotmail.com I also have pic'ts of the cracks "micro & macro" if you need to see them.