Joining Technology of Dissimilar Materials and Its Application in Complex Structure Manufacturing

doi:10.11900/0412.1961.2025.00263

Acta Metall Sin

2026, Vol. 62

Issue (5): 835-854 DOI: 10.11900/0412.1961.2025.00263

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Joining Technology of Dissimilar Materials and Its Application in Complex Structure Manufacturing

FENG Jicai¹^,², SONG Xiaoguo¹^,²(

), LIU Duo², ZHOU Li², TAN Caiwang², CHEN Bo²

1 State Key Laboratory of Precision Welding & Joining of Materials and Structures, Harbin Institute of Technology, Harbin 150001, China
2 Shandong Provincial Key Laboratory of Special Welding Technology, Harbin Institute of Technology at Weihai, Weihai 264200, China

Cite this article:

FENG Jicai, SONG Xiaoguo, LIU Duo, ZHOU Li, TAN Caiwang, CHEN Bo. Joining Technology of Dissimilar Materials and Its Application in Complex Structure Manufacturing. Acta Metall Sin, 2026, 62(5): 835-854.

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Abstract

Dissimilar material joining technologies play a critical role in enabling lightweight design and functional integration in complex structures and are widely applied in aerospace, equipment manufacturing, and transportation industries. However, significant differences in properties, such as thermal expansion coefficients, melting points, and metallurgical compatibility, pose major challenges. These disparities often result in poor interfacial bonding, the formation of excessive brittle intermetallic compounds, and high residual stresses within joints. This review summarizes major dissimilar material joining techniques, including brazing, diffusion bonding, friction stir welding, high-energy beam welding, and additive manufacturing, along with their applications in the fabrication of complex structures. Key scientific issues associated with these processes, such as interfacial bonding mechanisms, joint strengthening strategies, and structural reliability, are discussed, and future development trends are briefly outlined.

Key words: joining of dissimilar material complex structure interfacial bonding joint property

Received: 08 September 2025

ZTFLH:

TG454

Fund: National Natural Science Foundation of China(52175307);National Natural Science Foundation of China(52275318);Taishan Scholar Foun-dation of Shandong Province(tspd20240809);Taishan Scholar Foun-dation of Shandong Province(tsqn202312139)

Corresponding Authors: SONG Xiaoguo, professor, Tel: (0631)5687338, E-mail: songxg@hitwh.edu.cn

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	FENG Jicai
	SONG Xiaoguo
	LIU Duo
	ZHOU Li
	TAN Caiwang
	CHEN Bo

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https://www.ams.org.cn/EN/10.11900/0412.1961.2025.00263 OR https://www.ams.org.cn/EN/Y2026/V62/I5/835

Fig.1 Schematic illustration for Young's equation (θ—wetting angle)
(a) non-wetting (b) wetting

Table 1 Advantages and limitations of stress control methods of brazed joints^[3]

Fig.2 Schematic of friction stir welding (FSW)^[17]

Fig.3 Schematics of diffusion behaviors and interface microstructure evolutions of 301L stainless steel (SS) and 4043 Al alloy under different irradiation time (t)^[32]
(a-c) t < 0.4 s (d-f) t < 1.2 s (g-i) t < 2.0 s

Fig.4 Local cross-sectional topography analyses (including OM images, SEM images, and EDS elements distribution) of TC4/CFRTP with four modified types (CFRTP—carbon fiber reinforced thermal plastic)^[51]
(a-c) original surface
(d-f) silane coupling agent (SCA—silane coupling agent)
(g-i) micro-arc oxidation (MAO) modification
(j-l) SCA-MAO

Fig.5 Three composition gradient deposition forms of 20% (component A), 10% (component B), and 5% (component C) (a), variations of average primary dendritic arm spacing (PDAS) along the deposition direction (b), XRD patterns at different location obtained for component A (c), and fracture surfaces of the three gradient specimens (d)^[67]

Fig.6 Variations of contact angle with temperature for different Ti contents and corresponding projective images obtained by camera at 1050 ^oC (insets)^[3] (SAC—Sn_0.3Ag_0.7Cu)

Fig.7 TEM analysis results from the Si/Si₃N₄ interface of the Si₃N₄ ceramic after laser modification^[68]
(a) BF-TEM image
(b-d) SAED pattern (b), HETEM image and SAED pattern (inset) (c), and IFFT image (d) taken in marked A1 in Fig.7a (d—interplanar spacing)
(e-g) SAED pattern (e), HETEM image and SAED pattern (inset) (f), and IFFT image (g) taken in marked A2 in Fig.7a
(h, i) HRTEM images and SAED patterns (insets) taken in marked A3 in Fig.7a

Fig.8 Amorphous interface of Al/steel dissimilar metals^[20]
(a-c) bright field TEM image (a), HRTEM image (b), and EDS linear results at the interface (c) (d) comparison of formation enthalpies

Fig.9 Schematic of the assembly process of heterogeneous honeycomb sandwich structure^[98]

Fig.10 Propellant tank welding^[103] (RS—retreating side, AS—advancing side, D—diameter)
(a) prototype of propellant tank
(b) weld distribution

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