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A new joining method, termed resistance spot welding with a rivet, was tried to weld steel to aluminum alloy. Scanning electron microscopy studies of the interfacial microstructures revealed the presence of an FeAl reaction layer at the rivet/aluminum alloy interface, and of FeAl 3  at the steel/aluminum alloy interface. A tensile shear load of a maximum of 3.85 kN was obtained at a welding current of 21 kA. The results reveal that resistance spot welding with a rivet is an effective method for joining steel and aluminum alloy.

Joining steel to aluminum alloy by resistance spot welding with a rivet