If you’ve ever spent time in industrial maintenance, construction, or even basic DIY projects, you’ve probably dealt with two metal parts seizing up so tight you had to use a sledgehammer just to separate them. That crummy, permanent wear on the metal surfaces has a name: galling. And let’s be real—if you’re a gearhead, a plant manager, or just someone who fixes things for a living, galling is the worst. I get it, because I’m a washer supplier, and for years people have asked me point blank: “Can I use a washer to prevent galling?” Washers
The short answer is yes—but it’s not just grabbing any random washer off the shelf. I’ve seen way too many folks reach for a basic steel flat washer, toss it between two fasteners, and wonder why it still ended up with galling. That’s why I’m breaking this down straight, no fancy jargon, just what I’ve learned working with washers day in and day out, helping everyone from small job shops to big manufacturing plants fix this exact problem.
First, let’s keep it simple: what even is galling? It’s not just scratches. Galling happens when two similar metals rub together under pressure, right? Like, if you have a steel bolt and a steel nut tightening down, or two aluminum plates clamping together. The pressure forces the tiny peaks and valleys on each metal’s surface to break off, weld together temporarily, and then tear as you adjust the fastener. It’s a cold-weld thing, basically, and it can turn a simple assembly into a ruined part in minutes. Galling is super common because most standard fasteners and washers are made from the same material—cheap, easy to source, but that’s exactly the problem. Similar metals = higher galling risk.
So why would a washer help here? Let’s think about what a washer does normally. A flat washer spreads the load of a bolt so it doesn’t dig into the part or the head of the bolt, but that’s just its basic job. When you pick the right washer for galling, it acts as a barrier between the two rubbing surfaces. No direct metal-to-metal contact = no cold welding, no galling. That’s the core of it, but like I said, not all washers do this equally.
Let’s walk through the different scenarios where washers work for galling, and what kind of washer you actually need for each. I’ve got a few go-to types I recommend, based on what people are actually using.
First, dissimilar metal pairs. This is the big one. If you’re using, say, a steel bolt with aluminum parts? Aluminum is soft, so it galling super easy when pressed against steel. The solution here is a washer made of a third metal that’s compatible with both, or a coated washer. Wait—let’s clarify. If you put a zinc-plated steel washer between steel (bolt) and aluminum (part), that barrier prevents the two dissimilar metals from rubbing directly. No steel-aluminum contact, so no galling. I see so many people skip this and wonder why their aluminum plate has a huge, ragged mark where the bolt was. That’s galling, and a simple zinc-plated flat washer would’ve stopped it.
But wait, what if you’re dealing with two steel parts? Same metal is way harder to stop, because they have almost identical atomic structures, so they’re way more likely to weld together. Here, plain steel washers won’t cut it. You need a specialized washer, like a stainless steel one? No, wait—standard stainless steel can still gall against steel. I swear by lock washers? No, lock washers are for preventing loosening, not galling. My top pick for same-metal galling is a washer with a dry lubricant coating, like PTFE (that’s Teflon, to you) or molybdenum disulfide (moly). Those coatings create a slippery, non-weldable layer between the two metal surfaces. I had a customer last month who was assembling steel structural beams—they were having so much galling they had to replace 20 bolts a week. They switched to our PTFE-coated steel washers, and that problem went away entirely. No more replaced bolts, no more extra labor chipping away at the welds. That’s the stuff that works.
Another scenario: high-tension fasteners. If you’re tightening a bolt down really tight—like for heavy machinery, pressure vessels, or big construction projects—the pressure is way higher, so galling is way more likely. A basic flat washer here can’t handle that pressure on its own. I recommend spring washers? No, wait— Belleville washers, sometimes called disc springs, are the ones for high tension. They’re conical, so they flex under load, spread that tension evenly, and because they’re usually made of hardened steel or stainless with a coating, they don’t rub the bolt or the part directly. I had a plant manager tell me they’d go through sets of bolts every time they replaced a large motor on their assembly line. The high tension and vibration caused so much galling the bolts would seize before they could even tighten them all the way. Switched to our coated Belleville washers, and now a set of bolts lasts six months instead of one week. That’s a huge win for downtime.
Wait, let’s get one thing straight: washers aren’t a magic fix. If you’re using cheap, thin washers that deform under load, they’ll still cause galling. I’ve seen people buy those $1 boxes of generic flat washers from the hardware store, use them on a high-pressure application, and wonder why they still have galling. The thickness and material quality matter as much as the washer type. For example, a 1/16” thin washer won’t spread the load evenly, so the pressure is still concentrated in one spot—exactly where galling starts. You need a washer that’s the right size and thickness for the bolt size and the application. That’s something I help people with all the time—we’ll get a call, someone says “my galling won’t stop” and I ask, what size bolt, what materials, what’s the tension, and 9 times out of 10 they were using a washer that was too thin or the wrong material.
Also, let’s talk about when washers might not work. Wait, does that even happen? If you’re dealing with extreme high heat, like welding applications, or super corrosive environments? Then washers alone might not be enough, but they’re still part of the solution. For welding, for example, you might need a ceramic-coated washer to handle the heat, and that will prevent the fastener from galling as it expands and contracts from the heat. For corrosive stuff, a stainless steel or nickel alloy washer will stand up to the rust and prevent galling in damp, salty environments (like marine construction, I see you).
Let’s go back to that cold welding thing to make sure it clicks. Galling is basically two metals sticking together because their atoms are close enough that they bond chemically. A washer acts as a buffer—so the atoms of the two fastener parts never get close enough to bond. That’s why the material of the washer is key. If your washer is the same metal as the bolt, even a coated one, the coating is the buffer. If the coating wears off? Well, then you’re back to same metal, so you might get some galling, but a good coating lasts way longer than just the bolt’s initial use. I’ve tested our PTFE-coated washers—they can handle up to 10,000 tightens before the coating starts to wear, which is way more than a basic washer can.
I also want to clear up a common myth: some people think using lubricant is enough to prevent galling, and they skip the washer. Wait, lubricant is great, but if you have a weak lubricant or you’re working in a place where it can wash away (like outdoor construction), a washer is a secondary layer of protection. I had a contractor tell me they used graphite lube on their bolts, but still had galling because the rain washed the lube off. They added our zinc-plated washers, and even when the lube wore off, the washer’s barrier was still there. So combining a good washer with a lubricant is a one-two punch that works way better than either alone.
Let me give you a real quick example I have in my mind. Last quarter, a customer who makes agricultural equipment reached out. They were assembling plow blades, which use a lot of steel fasteners, and the constant dirt, moisture, and vibration was causing massive galling on their bolts. They tried regular steel washers, they tried lubricant, nothing stuck. We suggested our moly-coated steel flat washers—moly is super slippery, doesn’t wash off easily, and stands up to dirt. They switched, and not only did galling stop, their assembly time went down because they didn’t have to fight to tighten bolts anymore. That’s the kind of result I live for as a washer supplier.
Now, what if you’re a DIY guy working on a bike or a backyard project? The same rules apply, but you don’t need industrial-grade washers. If you’re using a steel bolt on steel, grab a zinc-plated washer from the hardware store—they’re cheap, easy to find, and will prevent most minor galling. If you’re using aluminum on steel, same thing: a zinc-plated washer works. Just don’t skip it. I’ve seen so many people ruin a nice bike frame because they skipped the washer and got galling on the bolt, making it impossible to remove later.
Wait, let’s address a question I get a lot: can I use any coated washer? No, not all coatings are the same. PTFE is great for low-friction, dry environments, moly is better for high pressure or areas where lubricant is hard to keep, ceramic coatings are for high heat. It’s not one size fits all. That’s why I always ask customers about their specific setup before suggesting a washer. I don’t just sell washers; I help solve problems, and galling is a problem that needs specific solutions.
Let’s wrap this up so you don’t have to scroll back through all the details. The answer to “Can I use a washer to prevent galling?” is a resounding yes—if you pick the right washer for your application. The key points are: galling happens when two similar metals rub together under pressure, a washer acts as a barrier between those surfaces to stop cold welding, different washer types work for different scenarios (zinc-plated for dissimilar metals, coated for same metals, Belleville for high tension), and cheap washers won’t cut it—you need the right material, thickness, and coating.
If you’re dealing with galling right now, or you just want to make sure your next assembly doesn’t turn into a war with seized bolts, reach out to us. We can help you figure out exactly what kind of washer you need, no fancy hoops to jump through, no sales pitch that doesn’t fit your project. We’re here to help solve your fastener problems, and galling is one we’ve dealt with a lot.
A354 Bolts Series References:
- "Galling Prevention in Fastening Systems," Industrial Fasteners Institute, 2022
- "Wear and Galling of Metals," ASM International, 2021
- "Design Guidelines for Preventing Galling in Mechanical Assemblies," Society of Manufacturing Engineers, 2020
Ningbo Taida Fastener Manufacture Co., Ltd.
Ningbo Taida Fastener Manufacture Co., Ltd. is well-known as one of the leading washers manufacturers and suppliers in China. Please feel free to buy high quality washers at competitive price from our factory. Good service and punctual delivery are available.
Address: No.286 Galaxy Road, Chengdong Industrial Park, Xiangshan Economic Development Zone, Ningbo China
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