The Replacement of Resistance Welding with Laser Beam Welding

Abstract Resistance welding has long been successfully used in the automotive industry, but nowadays, there are even more advanced technologies, such as laser beam welding, which is a much faster, more economical and flexible technology. During our work, we have mapped the possibility of replacing resistance welding with laser beam welding. Furthermore, we have found a solution to the problems occurring during laser beam welding. The biggest challenge in laser beam technology is that the zinc coating on the steel plates (required to prevent corrosion) evaporates during welding, resulting in pores, and leading to a significant reduction in weld strength. We have solved that by using spacer sheets, which allow the zinc vapour to escape from the keyhole.