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Joining feasibility of aluminium alloy to polypropylene sheets via friction stir lap joining was examined. Effects of heat-input on microstructure and mechanical behaviour of the joints were investigated. A covering plate was used to confine flow of molten polymer. The results showed a distinctive interaction layer at polymer/aluminium interface, consisted mainly of C, O and Al. Shear strength of the joints decreased by enhancement of the heat-input due to increase in the thickness of the interaction layer as well as the gap width between this layer and both aluminium and polymer matrices. Maximum shear-tensile strength of 5.1 MPa (∼20% of polymer shear strength) was obtained, which was higher than or comparable to that of the joints produced by other processes.