Abstract:
Aluminum/steel dissimilar metal composite structures provide remarkable advantages in achieving lightweight design and high performance. However, the significant differences in their physicochemical properties pose numerous challenges to welding, with the formation of brittle intermetallic compounds (IMC) at the interface being a key factor limiting joint performance. Arc fusion-brazing, owing to its low cost and flexible processes, has become one of the most promising joining technologies for engineering applications in this field. This paper reviewed the recent research progress in aluminum/steel dissimilar metal arc fusion-brazing, focusing on the technical characteristics and development status of different arc fusion-brazing processes including TIG, MIG, CMT, and composite arcs. It also analyzed the formation and growth mechanism of the Fe-Al IMC layer in depth, which was controlled through process optimization, filler wire element doping, and transition layer addition. Therefore,effectively suppressing the IMC layer thickness and improving its morphology and composition through synergistic control of heat input and interfacial reaction is crucial for obtaining high-performance aluminum/steel arc brazed joints. Further research on related mechanisms and process innovation remains a key focus for future studies.