Abstract
Local reinforcement of aluminum with laser welded patches of zinc-coated steel can effectively contribute to crashworthiness,
durability and weight reduction of car body. However, the weld between Zn-coated steel and aluminum is commonly susceptible
to defects such as spatter, cavity and crack. The vaporization of Zn is commonly known as the main source of instability in the
weld pool and cavity formation, especially in a lap joint configuration. Cracks are mainly due to the brittle intermetallic compounds
growing at the weld interface of aluminum and steel. This study provides a review on the main metallurgical and mechanical
concerns regarding laser overlap welding of Zn-coated steel on Al-alloy and the methods used by researchers to avoid the weld
defects related to the vaporization of Zn and the poor metallurgical compatibility between steel and aluminum.