Microstructural Characterization and Mechanical Properties of Laser Beam-Welded Dissimilar Joints between A6000 Aluminum Alloy and Galvanized Steel

This paper presents the laser beam welding process of a lap joint between galvanized steel (Z225) and an aluminum alloy (A6000) from an IPG fiber laser. Welding of steel to aluminum has become popular in the automotive industry as a means of reducing the total vehicle body mass. This approach reduces fuel consumption and, ultimately, carbon emissions. Laser welding parameters used to control heat input for the study were laser power ranging between 800 and 1200 W, as well as laser welding speeds between 2 and 4 m/min. Distinct features of the dissimilar joints were microscopically examined. The SEM-EDS technique was employed to study the intermetallic phases along the Fe-Al interface. The outcome revealed the presence of “needle-like phases” and “island-shaped phases” at high heat inputs. Traces of both Fe₂Al₅ and FeAl₃ phases were detected. For low heat input, there was evidence of insufficient fusion. Weld width was influenced by welding parameters and increased with an increase in heat input. Mechanical properties of the joints indicated that the microhardness values of the weld joints were higher than those of both base metals. The maximum tensile shear strength obtained was 1.79 kN for a sample produced at 1200 W and 3 m/min.