ABSTRACT The hybrid metal joining of aluminium alloy and steel has become the most intensively used candidate material for energy conservation and emission reduction in the automotive industry because of the comprehensive properties of low density, high strength and good corrosion resistance. In this work, experimental investigations were conducted on the laser beam oscillation welding of galvanised steel and aluminium alloy arranged in a lap configuration. Well-formed joints were successfully obtained with the aid of beam oscillating. Zigzag structures were observed at the interfacial area of Al–Fe joints instead of blocky structures due to the oscillation-driven effect of the beam. The stirring effect of the oscillating beam can promote the migration of the solute during the laser welding process, thus inhibiting the separation of components and decreasing the vulnerability to cracking. The interface zones of the laser-welded Al–Fe joints were principally made up of the Fe2Al5, FeAl, FeAl2, FeAl3 and Fe2Al5Zn0.4 phases. The joints welded with beam oscillation exhibited a tensile load and elongation amount of 1.07 kN and 0.775 mm, respectively, representing 115.67% of the loading capacity and 119.23% of the elongation compared to laser beam-welded joints without oscillation.
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