Friction stir butt welding of strain-hardened aluminum alloy with high strength steel

Dissimilar metal joining is challenging because of intermetallic compound (IMC) formation. Solid state welding techniques provide an opportunity. 5083-H116 aluminum alloy and HSLA-65 steel sheets were butt welded by friction stir welding. Joint strength and failure position were determined by IMC thickness and stress concentration at welded interface.