A novel spot welding process for dissimilar metal lap joints using a new tool with the tip made of spherical ceramics, i.e., "Friction Anchor Welding,'' was applied to three lapped sheets that consisted of an Al alloy
(1.0-mm-thick A5052
) and two steels
(0.6-mm- and 1.0-mm-thick SPCC
). Consequently, a steel projection was formed in the Al alloy sheet, and the sheets were welded at a plunge depth greater than 1.4 mm. The height of this steel projection increased with the plunge depth when the plunge depth was less than 2.2 mm; accordingly, the weld strength increased, and the tensile shear strength and the cross tensile strength reached approximately 3.8 kN
/point and 2.5 kN
/point, respectively. However, when the plunge depth was greater than 2.2 mm, the tip of the steel projection peeled off from the Al alloy, followed by cracks formation along the steel projection and the Al alloy interface, and the weld strength consequently decreased.
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