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Abstract
Joining of ZEK100 Mg alloy and Zn coated DP600 steel sheets is studied using refill friction stir spot welding (RFSSW). The RFSSW process involves a tool with independently moving sleeve and pin components, which rotate at a constant speed and penetrate into only the top sheet. Welds could be achieved, which exceeded 4.7 kN shear strength, using the following process parameters: 1800 rev min− 1 tool speed, 3.0 s welding time and 1.5 mm of penetration into the upper ZEK100 sheet. Scanning electron (SEM) and transmission electron microscopy (TEM) are used to characterise the Mg/steel interface. It is revealed that a continuous layer of FeAl2 particles accommodate bonding of the sheets, which appears to have originated from the galvanised coating on the DP600.