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<p>This study investigates continuous laser lap welding of AZ31B Mg alloy and 304 stainless steel, examining laser power effects on joint characteristics under constant processing parameters. Numerical simulations using COMSOL software elucidated thermal profiles during welding. Optimal mechanical performance occurred at 2100 W, while introducing a Cu interlayer enhanced interfacial stability and weld morphology by suppressing Mg evaporation and surface defects. The Cu-mediated interface facilitated metallurgical bonding through Mg2Cu and MgCu2 intermetallic compound formation, improving joint strength by 18.7% compared to direct welding. Microstructural analysis revealed that the Cu interlayer effectively mitigated thermal stress concentration and inhibited crack propagation. These findings demonstrate that strategic interlayer implementation enables reliable dissimilar joining of Mg/steel systems through controlled interfacial reactions and optimized energy input, providing insights for advanced multi-material structure fabrication.</p>

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The Influence of Laser Power and Cu Interlayer on the Laser Lap Welding of AZ31B Magnesium Alloy and 304 Stainless Steel

  • 期刊论文

  • 发表日期：

    2025年12月16日

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  • Jiaqi Wan,
  • Mengde Zhou,
  • Xikang Cheng,
  • Ying Yan

摘要

This study investigates continuous laser lap welding of AZ31B Mg alloy and 304 stainless steel, examining laser power effects on joint characteristics under constant processing parameters. Numerical simulations using COMSOL software elucidated thermal profiles during welding. Optimal mechanical performance occurred at 2100 W, while introducing a Cu interlayer enhanced interfacial stability and weld morphology by suppressing Mg evaporation and surface defects. The Cu-mediated interface facilitated metallurgical bonding through Mg2Cu and MgCu2 intermetallic compound formation, improving joint strength by 18.7% compared to direct welding. Microstructural analysis revealed that the Cu interlayer effectively mitigated thermal stress concentration and inhibited crack propagation. These findings demonstrate that strategic interlayer implementation enables reliable dissimilar joining of Mg/steel systems through controlled interfacial reactions and optimized energy input, providing insights for advanced multi-material structure fabrication.