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Beyond the assembling of components laser welding procedures are also increasingly applied in steel manufacturing. Reasons for this trend are: high joining velocities, concentrated heat input resulting in extremely thin heating zones, and nearly constant seam geometries along the welding line. So, for example, welding aggregates are installed at the beginning of electrolytic or hot-galvanizing manufacturing lines to join coils of different thickness or grade for continuous production, cf. Figure 1. To minimize shutdowns welding must be extremely reliable, since the joining zone of the ’endless strip’ has to resist high thermal and mechanical loads, such subsequent annealing, bending and tension. Failures lead to technical breakdowns, repairs, and loss of production, which should be avoided as much as possible. Moreover, the welding process must be such robust that material with imperfections, such as oxidations or materials ripples, would be also accurately joined. Welding defects, for instances cracks, pores or seam shrinkages, cf. Figure 2, lead to reduction of the cross-sectional area and, therefore, represent critical regions w. r. t. damage and failure. From the engineering point-of-view it is essential to know, whether residual stresses or heat-induced degradations of the materials strength following from joining become critical or not. This question can be answered by e.g. extensive experimental investigations, during which material combinations, geometries (i.e., thickness) and welding parameters such as joining velocity, welding power or laser caustic are varied. Subsequent tensile tests of the different seams yield the critical strength, which is compared with the loading conditions of the production line.

Modeling, Simulation and Experimental Studies of Distortions, Residual Stresses and Hydrogen Diffusion During Laser Welding of As-Rolled Steels