Pulsed laser welding was used in joining pure aluminum to stainless steel in a lap joint configuration. It is found that the mechanical properties of the laser joints were closely correlated with the bead geometry, i.e., penetration depth. In order to study the correlation, two typical laser welds with different penetration depths were analyzed. In high penetration depth (354 μm) joint, Al-rich Fe?Al IMCs with microcracks were formed at the Al/fusion zone (FZ) interface. The joint strength was found to be (27.2±1.7) N/mm and three failure modes were observed near the Al/FZ interface. In low penetration depth (108 μm) joint, Fe-rich Fe?Al IMCs without any defect were formed at the Al/FZ interface. The joint strength was found to be (46.2±1.9) N/mm and one failure mode was observed across the FZ.
