Abstract
The main objective of the current work was to produce sound Refill FSSW joints between AA6181-T4 aluminum and DP600 steel plates. The steel plates were used in two different surface conditions: with and without galvanized surface layer. The Taguchi statistical method was used to find out the set of parameters indicated to produce joint with higher mechanical resistance. Then, the possibility of joining these dissimilar metals using the Refill FSSW process was verified. Tool rotation speed and welding time were varied to observe its effect over the joint behavior. The results of lap shear tests showed that galvanized layers do not cause any substantial change on the final joint mechanical resistance, even though different joining mechanisms had been observed.
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