Abstract
A composite structural material with an “A1050 porous aluminum/SS400 dense steel plate” is fabricated by friction stir welding (FSW), which is used both for mixing blowing agent powder with aluminum plates and for lap joining aluminum and steel plates in the same process. It is shown that, after the aluminum plates are foamed, diffusion bonding is realized and an Fe-Al intermetallic compound is formed at the interface of porous aluminum and dense steel. This is because new surfaces of aluminum and steel plates are formed by FSW, and thus bonding is realized at the interface of these plates immediately after FSW.
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