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Lap joining of a pure aluminum plate and a low carbon steel plate was performed using friction stir spot welding. The aluminum plate was placed over the steel plate, a rotating welding tool was inserted into the aluminum plate, and the tip of the tool was dwelled above the aluminum/steel interface. Dwell time was controlled in the range of 0 to 120 seconds. The microstructure of the welding interface was examined by optical microscopy and scanning electron microscopy. Chemical composition analysis was carried out by energy dispersive X-ray spectroscopy. Welding was achieved for all dwell times. Refined grains were formed by plastic flow in the aluminum matrix close to the welding interface. Intermetallic compound layer was produced along the welding interface. Precise backscattered electron image observation and energy dispersive X-ray spectroscopy analysis revealed that the intermetallic compound layer consisted of an Al13Fe4 phase layer and an Al5Fe2 phase layer. The thickness of the layers increased in proportion to the square root of the dwell time. The parabolic coefficient K was 1.30×10−14 and 6.06×10−13 m2/s for the Al13Fe4 layer and the Al5Fe2 layer, respectively.

Growth Manner of Intermetallic Compound Layer Produced at Welding Interface of Friction Stir Spot Welded Aluminum/Steel Lap Joint