Dissimilar joining of galvanized high-strength steel to aluminum alloy in a zero-gap lap joint configuration by two-pass laser welding

•Defect-free two-pass laser partially penetrated lap joint of galvanized steel to aluminum was achieved.•The thickness of the Al-rich intermetallic compounds could be controlled by optimal parameters.•The dynamic behavior of the molten pool and keyhole were monitored by a high speed charge-coupled device camera.•The presence of zinc in the intermetallic compounds could improve the strength of the lap joints.

A welding procedure based on using two-pass laser scans is introduced for dissimilar joining of overlapped galvanized high-strength dual-phase (DP) steel DP590 to aluminum alloy (AA) 6061 sheets. The first pass is based on a defocused laser spot that scans across the top of the two overlapped sheets and heats the zinc coating at the faying surface to be melted and partially vaporized, while the second pass is executed with a focused laser spot in order to perform the welding. Completely defect-free galvanized steel to aluminum lap joints were obtained by using this two-pass laser welding procedure. An on-line machine vision system was applied to monitor the keyhole dynamics during the laser welding process. An energy-dispersive X-ray spectroscopy (EDS) was carried out to determine the atomic percent of zinc, aluminum, and iron in the galvanized steel to aluminum lap joints. Mechanical testing and micro-hardness test were conducted to evaluate the mechanical properties of the galvanized steel to aluminum lap joints. The experimental results showed that the lap joint of galvanized steel to aluminum obtained by the two-pass laser welding approach had a higher failure value than those joints obtained when the zinc at the faying surface was mechanically removed under the same welding speed and laser power.