Effects of Welding Speed on Microstructure and Properties of Laser Brazing-welding Joints for Aluminum/Steel Dissimilar Metals

SUN Youping; HE Chengwei; LI Wangzhen; LI Yang; ZHANG Kaifei; ZHANG Hai

doi:10.3969/j.issn.1674-6457.2026.07.013

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Journal of Netshape Forming Engineering ›› 2026, Vol. 18 ›› Issue (7) : 143-153. DOI: 10.3969/j.issn.1674-6457.2026.07.013

Advanced Joining Technology

Effects of Welding Speed on Microstructure and Properties of Laser Brazing-welding Joints for Aluminum/Steel Dissimilar Metals

SUN Youping^1,2,3,4, HE Chengwei¹, LI Wangzhen^1,2,3,4,*, LI Yang¹, ZHANG Kaifei¹, ZHANG Hai¹

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Abstract

The work aims to employ the laser brazing-welding method to investigate the effects of welding speed on the microstructural characteristics and mechanical behaviors of joints between 6061-T6 aluminum alloy and Q235A galvanized steel, to provide a theoretical basis for achieving highly reliable connections between dissimilar aluminum and steel materials in lightweight structures, suppressing the growth of brittle intermetallic compounds (IMCs), and enhancing joint performance. The 6061-T6 aluminum alloy and Q235A galvanized steel were joined by a laser brazing-welding process with a 1.2 mm diameter ER2319 filler wire at different welding speeds. The macroscopic morphology and microstructure of the joints were characterized by optical microscopy and scanning electron microscopy (SEM), while the phase composition at the interface was analyzed by X-ray diffraction (XRD) and energy dispersive spectroscopy (EDS). Mechanical properties were evaluated with a microhardness tester and an electronic universal testing machine, focusing on the evolution of joint structure and properties with the welding speed. The results indicated that sound bonding between aluminum and steel was achieved at welding speeds ranging from 0.9 m/min to 1.8 m/min, whereas incomplete penetration occurred at 2.1 m/min, leading to poor joint integrity. The weld microstructure at various speeds consisted mainly of droplet-like and acicular dendrites along with fine equiaxed grains. As the welding speed increased, the thickness of the IMC layer at the joint interface decreased progressively, with a maximum value of 28.94 μm. The optimal mechanical properties were obtained at a welding speed of 1.21 m/min, with peak microhardness and tensile strength reaching 154.3HV and 128 MPa, respectively. Fractographic analysis revealed a brittle fracture mode, and secondary phase compounds in the fracture surface were found to directly deteriorate the mechanical performance of the joints. In conclusion, during the laser brazing-welding process, the variation of the welding speed will change the welding heat input and the solidification conditions of the molten pool, thereby affecting the evolution of microstructure and the formation and growth of the interface IMC layer, and ultimately significantly influencing the mechanical properties of the welded joint. Therefore, optimizing the welding speed is the key to further improving the forming quality and comprehensive performance of aluminum/ steel dissimilar metal welded joints.

Key words

aluminum/steel dissimilar metals / laser brazing-welding / microstructure / intermetallic compounds / mechanical properties

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SUN Youping, HE Chengwei, LI Wangzhen, LI Yang, ZHANG Kaifei, ZHANG Hai. Effects of Welding Speed on Microstructure and Properties of Laser Brazing-welding Joints for Aluminum/Steel Dissimilar Metals[J]. Journal of Netshape Forming Engineering. 2026, 18(7): 143-153 https://doi.org/10.3969/j.issn.1674-6457.2026.07.013

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