Abstract
An enlarged pin head with circumferential notches for friction stir lap welding was proposed to achieve Al/steel joint with ultrastrong interface. The hook defect was eliminated. The effective interfacial width of 7.5 mm was achieved. The local silicon enrichment suppressed the growth of intermetallic compounds, which was attributed to the formation of an ultrathin interfacial layer containing a Fe4Al13 layer, a single Fe2Al5 layer, a bright Fe-rich layer, and a chaotic layer. The maximum tensile shear strength reached up to 442 N/mm.
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