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The effect of Zn interlayer on the microstructure and mechanical properties of dissimilar A1100 and SUS316L friction stir welded (FSW) butt joints was investigated. The results showed that Zn could improve the joint’s tensile strength. However, a complete dissolution of the Zn interlayer was necessary to achieve a sound joint. During the FSW process, the stirring action of the tool dispersed the Zn into the A1100 matrix forming a solid solution of Zn. A direct relationship was found between the tool rotational speed and the Zn dissolution rate. Also, the addition of Zn inhibited the Al–Fe IMCs growth, which played a positive role in the obtained tensile strength.

Effect of Zn interlayer on friction stir butt welding of A1100 and SUS316L stainless steel