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This work addresses to joining aluminum alloy AA6061 to carbon steel AISI 1006 sheets using the friction spot joining technique. The steel sheets were pre-holed and threaded with an internal M6 thread. The joining process was carried out by extruding the aluminum through the steel hole and thread using a rotating tool with friction between the tool and aluminum. Three process parameters were used: pre-heating time, rotating speed and plunging depth of the tool, with four levels for each parameter. The results indicated that the two materials joined by a micro-scale mechanical interlock at an interface line of a width ranged between  0.7  to ~  2.5 mm . The joint’s shear force reached a minimum and maximum value of  2000  and  2500 N , respectively. The plunging depth was the most effective factor affecting the amount of the extruded aluminum and the joint’s shear force.

Friction Spot Lap Joining of Aluminum Alloy AA6061 to Pre-Holed and Threaded Carbon Steel AISI 1006