The dissimilar metal joints of A3003 aluminum alloy and SUS304 stainless steel were newly designed and produced by multi-run lap Friction Stir Welding
(FSW
) technique. The joints produced were estimated on mechanical properties such as static and fatigue strength, cross-sectional observation and hardness distribution. The interface of the joint was of a reaction layer with approximately 200 to 300 nm thickness, which was identified as Al
13Fe
4 and Al
5Fe
2. Furthermore, FEM analysis on the multi-run lap FSWed joints was well corresponded to the result of joints strength tests. It was confirmed that a multi-run lap FSWed joint could achieve almost the same strength as an explosive welded joint if its shape and the position, number and direction of its FSW-passes were optimized.
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