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Fluxless fiber laser fusion welding-brazing with rectangular spot was used to produce joints between 6061-T6 aluminum alloy and galvanized steel with filler powder. The joints were evaluated by metallurgical analysis and mechanical properties testing. The results indicated that favorable joint with good figuration, no crack and pore were present with optimized welding parameters. Furthermore, the joint was characterized by layered and dendritic microstructure. The layered structure is composed of Fe2Al5. The dendritic part is identified as T1 and Fe4Al13 phases. In addition, failures were observed in the weld/ steel interface with brittle characteristics from the tensile test. The mechanical resistance of the joint is determined by the ratio of width of weld interface and the maximum thickness of interme-tallic compounds layer.
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