Laser welding of galvanized steel

Claim 1

A method for welding a first steel sheet member having a corrosion protective metallic zinc coating on major faces thereof to a second steel member to form a joint therebetween, said first member comprising a faying surface region and a joint-external surface region opposite said faying surface, said method comprising pretreating the first member to selectively remove the zinc coating from the faying surface region and the joint-external surface region thereof and applying a nickel-base coating onto said regions, assembling the members such that the nickel-base coated faying surface region lies adjacent a faying surface region of the second member, said second member faying surface region being substantially free of vaporizable zinc, and welding the assembly by scanning the nickel-base coated joint external surface region of the first member with a high energy density beam to fuse the members at the faying surface to produce a welded joint therebetween, whereby the nickel-base coating on the first member surface regions reduces weld porosity and enhances corrosion resistance of the joint.

Claim 2

A method for welding a first steel sheet member having a corrosion protective metallic zinc coating on major faces thereof to a second steel member to form a joint therebetween, said first member comprising a faying surface region and a joint-external surface region opposite said faying surface, said method comprising pretreating the first member to selectively remove the zinc coating from the faying surface region and the joint-external surface region thereof and applying a nickel-base coating onto said regions, assembling the members such that the nickel-base coated faying surface region lies adjacent a faying surface region of the second member, said second member faying surface region being substantially free of vaporizable zinc, and welding the assembly by scanning the nickel-base coated joint external surface region of the first member with a high energy density beam to fuse the members at the faying surface to produce a welded joint therebetween, whereby the nickel-base coating on the first member surface regions reduces weld porosity and enhances corrosion resistance of the joint.

Claim 3

A method for laser welding first and second galvanized steel sheet members, each member comprising a corrosion protective, thin metallic zinc coating on opposed major faces thereof and having a faying surface region and a joint-external surface region opposite the faying surface region, said method comprising pretreating each said surface region of each member by scanning the region with a laser beam and concurrently injecting a fine nickel powder into the beam to deposit nickel onto the region, said laser beam having an intensity and scanning at a rate sufficient to selectively vaporize the zinc coating from the surface region while minimizing melting of the underlying steel, and further to melt and coalesce the powdered nickel to produce a nickel-base coating on the region, assembling the pretreated members such that the faying region of the first member lies adjacent the faying region of the second member, and welding the assembly by scanning the pretreated external region of the first member with a laser beam having an intensity sufficient to fuse the members at the faying surfaces to form a joint therebetween, whereby the nickel-base coating in the regions during laser welding reduces weld porosity and enhances corrosion resistance of the welded joint.

Claim 4

A method for laser welding first and second galvanized steel sheet members, each member comprising a corrosion protective, thin metallic zinc coating on opposed major faces thereof and having a faying surface region and a joint-external surface region opposite the faying surface region, said method comprising pretreating each said surface region of each member by scanning the region with a laser beam and concurrently injecting a fine nickel powder into the beam to deposit nickel onto the region, said laser beam having an intensity and scanning at a rate sufficient to selectively vaporize the zinc coating from the surface region while minimizing melting of the underlying steel, and further to melt and coalesce the powdered nickel to produce a nickel-base coating on the region, assembling the pretreated members such that the faying region of the first member lies adjacent the faying region of the second member, and welding the assembly by scanning the pretreated external region of the first member with a laser beam having an intensity sufficient to fuse the members at the faying surfaces to form a joint therebetween, whereby the nickel-base coating in the regions during laser welding reduces weld porosity and enhances corrosion resistance of the welded joint.