Hot-dip Al coated steel sheet (HACSS) showed a typical solidified structure of Al-Si alloy; primary Al dendrite and Al-Si eutectic structure. Intermetallic compounds were found between the coating layer and the steel substrate. On the other hand, sputtered Al coated steel sheet (SACSS) represented a well-mixed structure of Al-Si. No intermetallics were observed. Heat resistance tests were carried out at 450?¡ãC and 500?¡ãC. HACSS was discolored at 450?¡ãC, but SACSS at 500?¡ãC. In this study, heat resistance experimental results are analyzed and discussed based on their microstructures of non-ferrous/ferrous metal hybrid system.