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Contrast experiments of lap joints among dissimilar AZ31B Mg alloy, Mg99.50, zinc-coated DP600 sheet, and non-zinc-coated DP600 sheet were made by friction stir keyholeless spot welding (FSKSW) and vacuum diffusion welding (VDW), respectively. Scanning electron microscopy (SEM) and energy disperse spectroscopy (EDS) were used to investigate the microstructures and components of the joints welded. The experimental results show that the FSKSW bonding method is a kind of compound mode that contains a mechanical connection and element diffusion fusion connection, in which mechanical connection has the main decisive function on joints of Mg/steel. Elements diffusion exists in the interfacial region of the joints and the elements diffusion extent is basically the same to that of VDW. The elements’ diffusion in Mg/steel using FSKSW is defined in the reaction between small amounts elements of the base metal and zinc-coated metals. The intermetallic compounds and composite oxide perform some reinforcement on the mechanical connection strength

The Role of Mechanical Connection during Friction Stir Keyholeless Spot Welding Joints of Dissimilar Materials