Laser fusion–brazing of aluminum alloy to galvanized steel with pure Al filler powder

•We show a new Al–Fe welding mode, laser beam welding with filler powder.•The zinc plating layer has played the role of flux, assuring the brazing properties.•The intermetallic compound layer was made up of Fe2Al5Zn0.4.•The maximum shearing strength of the joint can be achieved 174 N/mm.

The fusion–brazing connection of the dissimilar metal 5052 aluminum alloy/ST07Z steel was achieved by using the Nd:YAG laser with pure Al filler powder, and the effects of the laser power and powder feeding speed on the formation and mechanical properties of the resultant joints were investigated. The experimental results show that melting–brazing connection of 5052 aluminum alloy/galvanized steel can be successfully achieved, and the zinc plating layer has played the role of flux, assuring the brazing properties. The intermetallic compound layer was generated on the welded brazing interface. The joint exhibited a shear strength of 174 N/mm if the thickness of the intermetallic layer at the interface is about 6–7 μm.