Zero-gap laser welding

1. A method for laser welding a pair of metal members together, at least one of the metal members having a protective metal coating, the method comprising:

applying a thin layer of an alloying agent on at least one of the metal members;

placing one end of one of the metal members in overlapping relation to one end of the other metal member to form an overlapping section, such that the alloying agent is between the first and second members in the overlapping section with zero-gap; and

laser welding the metal members and the alloying agent together to form a weld, such that the protective metal coating becomes substantially alloyed with the alloying agent to form an alloy, and such that the extended solid solubility limit of the alloying agent in the weld is not substantially exceeded,

wherein the alloy agent comprises copper powder, the protective metal coating comprises zinc and the metal members comprise steel.

2. The method of claim 1 , wherein the metal members comprise steel, the protective coating comprises zinc, and the content of the alloying agent in the weld is not substantially more than about 0.5% for zinc coated.

3. The method of claim 1 , wherein applying a thin layer of alloying agent further comprises:

mixing copper powder in a solvent to form a mixture; and

applying a thin coat of the mixture.

4. The method of claim 1 , wherein applying a thin layer of alloying agent further comprises electrostatically spraying the alloying agent.

5. The method of claim 1 , wherein applying a thin layer of alloying agent further comprises thermally spraying the alloying agent.

6. The method of claim 1 , wherein applying a thin layer of alloying agent further comprises:

providing a thin layer of oil; and

spraying alloying agent on the thin layer of oil.

7. The method of claim 6 , wherein providing a thin layer of oil comprises using residual oil from stamping.

8. The method of claim 6 , wherein providing a thin layer of oil comprises applying a thin layer of oil.

9. The method of claim 1 , wherein laser welding further comprises:

vaporizing the protective coating to form a vapor; and

melting the alloying agent to form a liquid, the liquid trapping and absorbing the vapor to form the alloy.

10. The method of claim 1 , wherein the weld has a porosity less than about 2%.

11. The method of claim 1 , wherein the weld has zero porosity.

12. A method for laser welding a pair of overlapping metal members together, at least one of the metal members having a protective metal coating, the method comprising:

applying a thin layer of an alloying agent on at least one of the metal members between the metal members;

melting the protective metal coating and the alloying agent to form an alloy, the alloy disposed between the overlapping members with zero cap;

laser welding the overlapping metal members together to form a weld with zero gap; and

controlling the amount of the alloying agent such that the extended solid solubility of the alloying agent in the weld is not substantially exceeded,

wherein the alloying agent comprises copper powder, the protective metal coating comprises zinc and the metal members comprise steel.

13. The method of claim 12 , wherein applying a thin layer of alloying agent further comprises:

mixing copper powder in a solvent to form a mixture; and

applying a thin coat of the mixture.

14. A weld joint formed by laser welding, the joint comprising:

a pair of overlapping metal members defining an overlapping section with zero gap, at least one of the metal members having a protective coating;

an alloy between the overlapping metal members at the overlapping section, the alloy formed by the protective coating and a thin coating of alloying agent on one of the overlapping metal members, the alloying agent comprises copper powder; and

a weld formed from a metal melt pool of the metal members, wherein the extended solid solubility limit of the alloying agent in the weld is not exceeded.

15. The weld joint of claim 14 , wherein the weld has a porosity less than about 2%.

16. The weld joint of claim 14 , wherein the weld has zero porosity.

17. The weld joint of claim 14 , wherein the metal members comprise steel, the protective coating comprises zinc, and the content of the alloying agent in the weld is not substantially more than about 0.5%.

18. The weld joint of claim 14 , wherein the metal members comprise steel and the protective coating comprises zinc.

19. The weld joint of claim 14 , wherein the alloy comprises brass.

20. The weld joint of claim 14 , wherein the copper powder has a mesh size of about 325 (about 40 micron).