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<p>Pulsed gas metal arc welding (GMAW-P) is increasingly used to join galvanized advanced high-strength steels in automotive manufacturing; however, liquid metal embrittlement (LME) remains a critical reliability issue due to zinc (Zn) transport under lap-joint confinement. This study compares conventional gas metal arc welding (GMAW) and GMAW-P on galvanized CP780 lap joints using three variants within a controlled heat-input window (<i>Q</i> = 202–242&#xa0;J/mm) and pulsing parameters (<i>I</i><sub><i>p</i></sub> = 283–313&#xa0;A, <i>f</i> = 8–10&#xa0;Hz). Macro/microstructural characterization by optical microscopy and scanning electron microscopy/energy-dispersive spectroscopy (SEM/EDS) shows that Zn vaporization and restricted venting increase interfacial pressure, promoting Zn-driven LME with cracks localized at the weld–lower-plate interface. Moderate pulsing (283&#xa0;A, 8&#xa0;Hz) reduced crack extension, whereas higher Ip/f promoted longer interfacial crack paths and Mn–Ti–Al–Si segregation films along crack walls. Fe–Zn intermetallic compounds (IMCs) were qualitatively inferred from SEM/EDS morphology and compositional trends as contributors to interfacial degradation.</p> Graphical abstract <p></p>

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Study of segregation and intermetallic compounds at the weld metal-base metal interface in galvanized AHSS steel: Impact on joint integrity

  • 期刊论文

  • 发表日期：

    2026年4月15日

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  • Carlos Adrián García-Ochoa,
  • Maleni García-Gómez,
  • Jorge Alejandro Verduzco-Martinez,
  • Francisco Fernando Curiel-Lopez,
  • Víctor Hugo Lopez-Morelos,
  • José Jaime Taha-Tijerina,
  • Julio Cesar Verduzco-Juárez

摘要

Pulsed gas metal arc welding (GMAW-P) is increasingly used to join galvanized advanced high-strength steels in automotive manufacturing; however, liquid metal embrittlement (LME) remains a critical reliability issue due to zinc (Zn) transport under lap-joint confinement. This study compares conventional gas metal arc welding (GMAW) and GMAW-P on galvanized CP780 lap joints using three variants within a controlled heat-input window (Q = 202–242 J/mm) and pulsing parameters (Ip = 283–313 A, f = 8–10 Hz). Macro/microstructural characterization by optical microscopy and scanning electron microscopy/energy-dispersive spectroscopy (SEM/EDS) shows that Zn vaporization and restricted venting increase interfacial pressure, promoting Zn-driven LME with cracks localized at the weld–lower-plate interface. Moderate pulsing (283 A, 8 Hz) reduced crack extension, whereas higher Ip/f promoted longer interfacial crack paths and Mn–Ti–Al–Si segregation films along crack walls. Fe–Zn intermetallic compounds (IMCs) were qualitatively inferred from SEM/EDS morphology and compositional trends as contributors to interfacial degradation.

Graphical abstract