It's still a rare process, but friction welding of steel and aluminium
has been around for some years.
Aluminium isn't difficult to weld, it's just that tricky surface layer.
Friction welding goes right through it.
Still sounds like a corrosion starting point to me. (As one who
remembers the Austin Heally 3000 with aluminum outer fender attached to
steel inner fender and the resulting line of corrosion on the aluminum
Every modern Navy ship since the '70s has been built with a steel hull and
aluminum superstructure. They are joined with square strips of bimetal which has
been explosion welded together. They seem to work fine. Save a whole lot of
weight. Bet they're glad now that fuel prices are in the sky .. - GWE
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