Informatics and Engineering Systems Faculty Publications

A snapshot review on Zn-induced porosity control in lap welding of galvanized CP780 complex-phase steel

Document Type

Article

Publication Date

5-12-2026

Abstract

Complex-phase (CP) steels are fundamental to modern automotive lightweighting strategies, combining high strength and energy absorption with reduced vehicle mass. To ensure durability, these steels are typically galvanized; however, the zinc coating introduces critical welding issues. During welding in lap joints, zinc vaporizes at ~ 906 °C, generating bubbles that often remain trapped beneath the solidifying weld pool, leading to porosity and compromising joint integrity. This discontinuity is particularly relevant in crash-critical applications, where even small pores may  jeopardize frame performance. Pulsed gas metal arc welding (GMAW-P), widely adopted in automotive production, provides a flexible process framework in which parameter control directly influences weld pool dynamics and porosity evolution. This snapshot review consolidates recent progress in understanding Zn-induced porosity mechanisms and highlights strategies for its mitigation, spanning parameter optimization, consumable design, and joint configuration. By bridging materials science with process engineering, practical insights are offered into improving weld reliability of galvanized CP steels.

Comments

https://rdcu.be/fqe0N

Publication Title

MRS Advances

DOI

10.1557/s43580-026-01662-z

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