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<p>To address the inherent sensitivity of conventional laser welding to assembly gaps in automotive manufacturing, this study proposes a novel wire-free galvanometer scanning laser (GSL) welding process for QP980/DP780 dissimilar advanced high-strength steels (AHSS). By systematically evaluating the joint forming quality and mechanical properties within the gap range of 0–0.5&#xa0;mm and comparing them with the non-scanning laser (NGSL) welding process, the gap tolerance threshold of the GSL process was investigated. The results show that the NGSL process exhibits significant sensitivity to gaps, with welding failure occurring when the gap exceeds 0.2&#xa0;mm. In contrast, the GSL process successfully achieves reliable bridging of gaps up to 0.5&#xa0;mm, representing a 2.5-fold increase in gap tolerance. Although mechanical properties gradually decay with increasing gap size, within the 0.3–0.4-mm gap range, the strength of GSL joints reaches 103% of that of the DP780 base metal, and the ductility is essentially consistent with that of the QP980 base metal. The synergistic optimization of gap adaptability, joint integrity, and base metal matching performance is attributed to the unique spatially modulated energy deposition mode of the GSL process, which promotes uniform material melting and enables efficient gap bridging. The findings of this study confirm that the GSL process is an effective solution to address the gap sensitivity in body-in-white welding, providing important theoretical foundations and engineering references for breaking through the technical bottleneck of zero-gap-tolerance assembly. </p>

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Effect of gap distance on forming and properties of laser welded joints of QP980/DP780 dissimilar steels

  • 期刊论文

  • 发表日期：

    2025年8月18日

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  • Yan Liu,
  • Jiahao Wang,
  • Wenguang Zhang

摘要

To address the inherent sensitivity of conventional laser welding to assembly gaps in automotive manufacturing, this study proposes a novel wire-free galvanometer scanning laser (GSL) welding process for QP980/DP780 dissimilar advanced high-strength steels (AHSS). By systematically evaluating the joint forming quality and mechanical properties within the gap range of 0–0.5 mm and comparing them with the non-scanning laser (NGSL) welding process, the gap tolerance threshold of the GSL process was investigated. The results show that the NGSL process exhibits significant sensitivity to gaps, with welding failure occurring when the gap exceeds 0.2 mm. In contrast, the GSL process successfully achieves reliable bridging of gaps up to 0.5 mm, representing a 2.5-fold increase in gap tolerance. Although mechanical properties gradually decay with increasing gap size, within the 0.3–0.4-mm gap range, the strength of GSL joints reaches 103% of that of the DP780 base metal, and the ductility is essentially consistent with that of the QP980 base metal. The synergistic optimization of gap adaptability, joint integrity, and base metal matching performance is attributed to the unique spatially modulated energy deposition mode of the GSL process, which promotes uniform material melting and enables efficient gap bridging. The findings of this study confirm that the GSL process is an effective solution to address the gap sensitivity in body-in-white welding, providing important theoretical foundations and engineering references for breaking through the technical bottleneck of zero-gap-tolerance assembly.