Resistance rivet-welding of aluminum alloy and steel

A new joining method termed resistance rivet-welding was tried to weld steel/aluminum alloy. The interfacial microstructure was observed by using scaning electron microscopy. A reaction layer of FeAl was observed at the rivet/aluminum alloy interface, whereas the reaction product of FeAl₃ was detected at the interface between steel and aluminum alloy. The joining between steel Q235 and rivet was sound. The maximum tensile shear load of 3.85 kN was obtained at welding current of 21 kA. The results reveal that resistance rivet-welding is a relatively effective method for joining steel and aluminum alloy.