<p>Al-Si coated 22MnB5 steel has been widely used in automotive manufacturing applications in the press hardened state and has become a key material to achieve lightweight and safety improvement. In the process of laser welding, the weld mechanical properties are deteriorated due to <i>δ</i>-ferrite precipitation caused by the Al-Si coating. To solve this problem, the common solution is to remove the Al-Si coating by laser ablation before welding. Despite its high cost and time involved, it is still widely adopted by the tailored blank manufacturers. In this work, laser welding with filled wire with three different chemical composition combinations has been developed to manufacture Al-Si coated steel tailored blanks. With this new manufacturing process, the formation of <i>δ</i>-ferrite can be inhibited without removing the coating. The experimental results show that Al element segregation exists in the fusion zone (FZ) of the welded joint, and the microstructure is a multiphase microstructure of <i>δ</i>-ferrite, <i>α</i>-ferrite and lath martensite (LM). When C-containing filler wire is used, there is still a certain amount of <i>δ</i>-ferrite in FZ, and the martensite type is changed from LM to high hardness and brittle twin martensite (TM). When Mn-containing filler wire is used, the full LM is obtained in the FZ, but there are shrinkage holes. Therefore, the mechanical properties of the above three kinds of welds still can’t meet the standards. When Ni-containing filler wire is used, Al segregation in the FZ is reduced, no <i>δ</i>-ferrite is detected in the FZ, and the microstructure is high density LM. In the tensile shear test, the tensile pattern is broken at the base metal, accompanied by obvious necking fracture. The tensile strength and microhardness of welded joints are increased by 50.6 and 26.3&#xa0;pct, respectively, compared with the welded joints without filler wires.</p>