Static and fatigue strength of laser-beam-welded steel-aluminium lap joints

Abstract This study investigates the laser beam welding of steel to aluminium plates using a lap joint configuration, emphasising the potential of dissimilar material designs for achieving lightweight components. It focuses on both the welding process and the static and fatigue strength characteristics of the welded joints. Specimens were tested under static loads and cyclical fatigue conditions to determine the endurable stresses. A comparative analysis was conducted against the endurable nominal stresses of T-stake welded joints, providing insights into the mechanical behaviour and durability of steel-aluminium connections. On the one hand, the findings underscore the significant influence of welding parameters on joint performance, revealing how an adequate welding process can enhance the strength and longevity of dissimilar metal joints in structural applications. On the other hand, robustness of laser beam welding is shown as the expected variations in the welding process lead to minor deviations on the tensile and fatigue strength.