Effect of gap clearance on the mechanical properties of weld-brazed lap joints

Gas metal arc brazing (GMAB) is a non-fusion joining process used in the automotive industry for joining thin-gauge Zn-coated steel sheets to other steels or dissimilar metals. Unlike torch brazing, GMAB does not rely on capillary action to form a joint. Consequently, gap clearance has not been considered important for lap joining applications. In this study, the effect of gap clearance on the mechanical properties of arc-brazed lap joints was investigated experimentally and verified using finite element modeling (FEM). The results showed that the gap clearance of lap joints played a critical role in controlling the joint strength.