Progressive developments and challenges in dissimilar laser welding of steel to various other light alloys (Al/Ti/Mg): A comprehensive review

In recent days, the utilization of lightweight alloys for various applications has been increased massively. Starting from the automobile industry, aerospace industry, and even in the biomedical field, there is a need for dissimilar precise joining of steel to other light alloys (magnesium alloy, aluminum alloy, titanium alloy). However, those alloys are characterized by different melting temperatures, machinability, strength, thermal conductivity, and oxygen reactivity. Considering this welding to challenge ongoing laser welding efforts to improve laser welding quality by altering the welding techniques, modes, proper use of shielding gasses, using suitable process parameters, and even proper joint and surface preparations are discussed. The feasibility of implementing all those things in the industrial setup can be understood only after analyzing recent works. Changes in microstructure and the defects (solidification cracking, intermetallic components formation, porosity) arrived during and after laser welding of these materials are reviewed. The paper also highlights the effect of shielding gas, welding speed, laser power, defocusing position, etc. during laser welding of lightweight materials. The critical issues related to dissimilar laser welding of these combinations and some remedial measures are discussed. The purpose of this review is to emphasize and understand the recent trends of dissimilar laser welding and explore the scope of industry level applications.