Cast aluminum alloy, AC4CH-T6, and wrought aluminum alloy, A6061-T6, werejoined by means of friction stir welding (FSW) technique. The effect of microstructure and post heat treatment on fatigue behavior of the dissimilar joints was investigated. Near the weld centre, Vickers hardness was lower than in the parent metals and the hardness minima were observed along the trace route ofFSW tool’s shoulder edge. Tensilefracture tookplace on A6061 side where the hardness was minimal, resulting in the lower static strength of the dissimilar joints than AC4CH or A6061. Fatigue fracture occurred on AC4CH side due to casting defects and the fatigue strength of the dissimilarjoints was similar to that of AC4CH, but lower than that of A6061. Friction stirprocess (FSP) andpost heat treatment successfully improved thefatigue strength of the dissimilarjoints up to that of the parent metal, A6061.
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