Laser Weld Galvanized Steel – 90% Less Zinc Fumes • No Arc Radiation • Zero Spatter

1. Zinc Vapor Explosions and Porosity
The boiling point of zinc is significantly lower than that of steel.

During welding, the zinc evaporates first, generating high-pressure vapor that easily triggers micro-explosions; this results in the formation of pores and blowholes, thereby compromising the stability of the weld seam.

👉 Our Solution: Employ oscillating welding to enlarge the weld pool size, and create venting channels on the underside or edges of the joint to allow zinc vapor to escape.

2. Spatter and Welding Instability
The escape of zinc vapor causes metal spatter and destabilizes the laser melt pool.

This leads to rough, uneven weld seams, poor surface quality, cumbersome post-processing requirements, and reduced overall efficiency.

👉 Our Solution: Select argon as the shielding gas and position the laser focus slightly above the workpiece surface (+1 to +2 mm); this reduces internal keyhole pressure and slows down the rate of zinc evaporation.

3. Coating Damage and Corrosion
Laser welding frequently burns away the zinc coating surrounding the weld seam, stripping the material of its corrosion protection.

This renders the area susceptible to oxidation and rust, ultimately shortening the product’s service life.

👉 Our Solution: Remove the galvanized coating along the designated weld seam area, and apply anti-corrosion treatment upon completion of the welding process.

4. Hazards of Toxic Zinc Fumes
Why is welding galvanized steel dangerous?

The evaporation of zinc generates zinc oxide fumes and dust, which can trigger “metal fume fever” and irritate the respiratory tract.

The risks associated with this process are significantly higher when operations are conducted in enclosed environments.

👉 Our Solution: Install and utilize a fume extraction system, and wear a dust mask.