A new technique for laser welding of galvanized steel in lap configuration is presented followed by test results. In galvanized steel welding, zinc is the main source of porosity because of its low boiling point. The paper describes a novel alloying based lap welding technique of zinc coated steels which delivers sound and reproducible welds with negligible porosity. Mechanical testing and X-Ray elemental mapping results of the samples made using this technique are also presented for validation.

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