Influence of Joint Configuration on Mechanical Properties of Laser Weld-Brazed Aluminum to Steel Joint

In the present work, laser weld-brazing experiments were performed to produce aluminum to galvanized steel joints in lap and flange configuration. Tests were carried out using Al-12 % Si eutectic filler wire for joining of AA6082 -T6 with galvanized steel with varying laser power and keeping other parameters (wire feed and laser scan speed) constant. Microstructural characteristics of the laser brazed joints, studied by SEM, revealed cast structure in the brazed zone. Intermetallic formed at the steel interface was non-uniform. From the hardness results, it was noted that the brazed region exhibits lower hardness compared to the base material. The wetting length was improved with increasing filler wire rate, which in turn improved the strength of the brazed joint in both the configuration (lap and flange). At 4 kW laser power, flange configuration sample has failed in AA6082 whereas, in case lap joint, failed in the heat affected zone of AA6082.