Influence of alloy elements on microstructure and mechanical property of aluminum–steel lap joint made by gas metal arc welding

5052 aluminum alloy sheets and galvanized mild steel sheets were joined in lap configuration by alternate-current double pulse gas metal arc welding with pure Al, Al–5Si, Al–12Si and Al–4.5Mg (wt%) filler wires. The effect of alloying elements on the microstructure of intermetallic compounds (IMC) layers formed between weld seam and steel, and tensile strength of the resultant joints were investigated. The thickness of IMC layer in all samples varied along the cross-section of the joint, the intermediate part of the IMC layer was thicker than the head and root parts. The diffusion of Si into Fe2Al5 sub-layer could restrain the growth of Fe2Al5 sub-layer and IMC layer, and joint's mechanical property improved with the increasing Si content in Fe2Al5 phase. Due to the high hot crack sensitivity of Al–4.5Mg alloy, cracks generated at the root of joint made with Al–4.5Mg filler, resulting in poor mechanical property.