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Ultrasonic Spot Welding of Aluminum to High-Strength LowAlloy Steel: Microstructure, Tensile and Fatigue Properties V.K. PATEL, S.D. BHOLE, and D.L. CHEN The structural applications of lightweight aluminum alloys inevitably involve dissimilar welding with steels and the related durability issues. This study was aimed at evaluating the microstructural change, lap shear tensile load, and fatigue resistance of dissimilar ultrasonic spotwelded joints of aluminum-to-galvanized high-strength low-alloy (HSLA) steel. Two non-uniform layers were identified in between Al and HSLA steel via SEM/EDS and XRD. One was an Al-Zn eutectic layer and the other was a thin (

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