Journal of Materials Science, Vol.31, No.24, 6595-6607, 1996
Laser-Welding of Al55-Zn Coated Steel Sheet
A study has been made of the procedures used for the lap and butt welding of 0.62 and 1.16 mm thickness steel sheets coated with Al55-Zn alloy, using laser-beam technology. The main problems arise in lap welding as a result of zinc evaporation from the coating. The vapour pressures of this element lead to cratering and blistering of the welds which are visible from the external surface and imply severe weld defects. An efficient solution to this problem consists in leaving a gap between the internal faces, thus allowing the zinc vapours to escape. Excessive gaps, however, lead to the molten metal collapse and to lack of penetration. In the present work, acceptable results were obtained with a maximum interface separation of 0.1 mm. This allows excellent continuity of the joints, without cracks, pores or non-metallic inclusions and with moderate hardnesses, thus demonstrating the good laser weldability of the coated material. A difficulty arises, however, in relation to the coating in zones close to the weld. In these high-temperature zones the coating is lost, and in the immediately adjacent areas the coating microstructure and phases are altered, as was shown by scanning electron microscope analyses.