The in-process monitoring of $CO_2$ welding of Zn-coated steel plates has been studied and compared with that of conventional thin plates. Relationships between weld defects and plasma emission signals were evaluated in laser lap joint of thick Zn-coated steel. According to the study, weld defects were found to increase with Zn content. As a result, measured plasma emission signals also decreased. In case of plate with $15{mu}m$-thick Zn-coated layer, defects caused by evaporation of Zn could, therfore, controled by gap of 0.1mm, resulting in a stable emission signals. However, the amplitude of signals fluctuated very widely. Variation of amplitude sould be limited in 3-8V by FFT smoothing.