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Aluminium and copper plates with 3 mm thickness were successfully friction stir lap welded at a lower rotation rate of 600 rev min 21 using a larger pin 8 mm in diameter. Good metallurgical bonding on the Al/Cu interface was achieved due to the formation of a thin, continuous and uniform Al-Cu intermetallic compound layer. Furthermore, many Cu particles consisting of pure Cu and intermetallic compound layers were generated at the lower part of the nugget zone, forming a composite structure with increased hardness. A lower rotation rate resulted in a decrease in annealing softening in the heat affected zone (HAZ), and a larger diameter pin increased the Al-Cu bonding area. These factors resulted in that the friction stir welded lap joint exhibited a high failure load of 2680 N with failure in the HAZ on the aluminium side.