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The ability to laser weld automotive components is a determining factor in converting the currently specified wrought or cast materials to powder metallurgy (P/M) parts for various applications. Material selection, process conditions and joint design are known to have a significant influence when fusion welding P/M components. Welding trials were conducted to determine the appropriate laser parameters for several P/M grades at various density levels. Bead-on-plate, overlap and butt joint designs were attempted, primarily without filler metal additions.

The paper identifies welding methods that are most often used to join P/M automotive components. Various weld procedures associated with the different methods are discussed. Examples are presented along with appropriate process information. A more detailed application development involves Gas Tungsten Arc welding a stainless P/M exhaust bushing to a wrought stainless steel tube.