Cold metal transfer process is applied to join titanium and Q235 steel with copper filler metal. Scanning electron microscope (SEM), energy dispersive spectrometer (EDS) analysis, micro-hardness tests, and tensile strength test were performed to investigate the joining mechanism and strength of joints. The results show that the stacking order of two base metals affected the joining modes and strength. For top Q235 steel to bottom Ti-TA2 lapped joint, there was no distinct interface reaction layer between the steel base metal and the weld metal; dispersed TiFe2 intermetalics (IMCs) IMCs between the steel base metal and the Ti base metal greatly improved the strength of joint; the tensile force of the joint could reach up to 93% that of steel-steel joint using the same welding parameters. Additionally, the joints were fractured in dimple mode at the steel base metal. For top Ti-TA2 to bottom Q235 steel lapped joint, the increasing volume fraction of Ti-Cu IMCs at the Ti-Cu weld metal interface contributed to the strength of joint degradation. The joints under tensile loading are initiated at the Ti-Cu weld metal interface between the weld metal and Ti base metal, then propagated to weld metal, finally fractured with brittle mode.
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