Method of connecting aluminum alloy die cast member

A method of connecting aluminum alloy die cast members, comprising:

• allowing an intermediate material in the form of a powder made of aluminum alloy to intercalate between mutually connecting surfaces of the die cast members made of aluminum alloy, the die cast members are configured to generate heat by turning on electricity and are connected while mutually pressing, the die cast member and/or intermediate material contains 0.3 to 2.5 wt % of magnesium, the intermediate material is constituted of powder having an average particle size of 10 to 250 μm, and the die cast members have positioning parts for setting a mutual position where the die cast members connect at a different position from the connecting surface;
• providing the connecting surface which comes in contact with the intermediate material of a rough surface having a surface roughness of 20 to 300 μm to enhance electric resistance between the connecting surfaces of die cast members and the intermediate material;
• providing a spacer between the die cast members, the spacer being made of an electric insulation and being different from the intermediate material, the spacer intercalates between the positioning parts of the die cast members;
• pressing the die cast members after the intermediate material intercalates between the connecting surfaces of the die cast members;
• and
• applying electric current to the die cast members and the intermediate material through respective connecting surfaces, the connecting surfaces allowing heat generation at a temperature suitable for non-melt connecting, whereby the die cast members are connected while performing reduction of an aluminum alloy oxide membrane by magnesium, and an interval between the die cast members is determined by a thickness of the spacer.