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Laser Welding of Dual-Phase Galvanized Sheet Steel



Stephanie L. Miller, Erik A. Pfeif, Andrei F. Kazakov, Esther Baumann, Marla L. Dowell


Laser welding has many advantages over traditional joining methods, but remains underutilized. NIST has undertaken an initiative to improve predictions of weldability, reliability, and performance of laser welds. This study investigates butt welding of galvanized and ungalvanized dual-phase automotive sheet steels (DP 590) using a 10 kW commercial fiber laser system (IPG). Parameter development work, hardness profiles, microstructural characterization, and optical profilometry profiles are presented. Sound welding was accomplished in a laser power range of 2 kW to 4.5 kW and travel speed of 2000 mm/min to 5000 mm/min. Hardness ranged from nominally 200 HV to 400 HV across the welds, with decreased hardness across the HAZ directly correlated to the appearance of ferrite. A program was developed to non-destructively evaluate weld quality based on geometrical criteria. Profilometry data were compared between light optical, metallographic sample, and frequency-modulated continuous-wave laser detection and ranging (FMCW LADAR) methods. Speckle noise in the LADAR data did not allow for accurate representation of the weld profile.
Proceedings Title
Proceedings of SPIE Photonics West 2016
Conference Dates
February 13-18, 2016
Conference Location
San Francisco , CA
Conference Title
SPIE Photonics West 2016


laser welding, low-carbon steel


Miller, S. , Pfeif, E. , Kazakov, A. , Baumann, E. and Dowell, M. (2016), Laser Welding of Dual-Phase Galvanized Sheet Steel, Proceedings of SPIE Photonics West 2016, San Francisco , CA, [online], (Accessed May 17, 2024)


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Created March 18, 2016, Updated November 10, 2018