The lap joints of upper Al alloy sheets (1.0-mm-thick A5052) and lower Zn-coated steel sheets (1.2-mm-thick GI steel or GA steel) were welded using insert steel sheets (0.6-mm-thick SPCC) by a spot welding process with a tool having a spherical ceramic tip, i.e., "Friction Anchor Welding." As a result, straight (not-rugged) steel projections were formed in the Al alloy sheets for both the GI and GA, while steel projections were not formed for the GI, rugged steel projections were formed for the GA without the insert steel sheets. In addition, the tensile shear strength for the GI was greater than that for the GA. In other words, the tensile shear strengths reached about 3.9 kN/point for the GI and about 3.2 kN/point for the GA, which were greater than those of the welds without the insert steel sheets. On the other hand, the cross tensile strengths for the GI and GA were almost the same, which reached about 2.6 kN/point. Additionally, for the GI, the Zn layer on the GI steel sheet melted and was totally removed due to the pressure and heat caused by the rotating tool, which facilitated the welding between the SPCC and GI steel sheets. For the GA, however, the Zn-Fe layer on the GA steel sheet changed to a solid-liquid mixture and was not completely removed, which prevented the welding between the SPCC and GA steel sheets. Therefore, the thickness of the steel-steel welded region (i.e., the SPCC-GI or the SPCC-GA welded region) for the GI was greater than that for the GA. We estimated that the difference in this thickness is significantly related to the fracture mechanism during the tensile shear test and the cross tensile test.
