The set of joints between dissimilar materials gained to a very important goal for joining specialists in the last decades. In automotive the increased interest in light weight concepts leads to set in a component contemporarily different light weight metals. Furthermore in other sectors of industrial application joining of dissimilar materials is a focus point. Diffusion welding represents a very attractive joining technology for advanced materials, especially when conventional fusion welding processes degrade the properties of the materials in the heat affected zone and in the melt pool, as it is performed at temperatures between 0,5 and 0,8 of the melting temperature.

Diffusion welding offers the unique possibility to achieve a metallurgical joining in the solid state without low melting filler, thus avoiding large brittle intermetallic phases, which form in the melt pool while cooling. In this paper the joining of aluminum to titanium will be presented. As aluminium can be dissolved till about 10 at.-% in the -Ti crystal for temperatures below 550C, the formation of brittle intermetallic phase can be avoided. First investigations were performed on Al99,5 and cp-Ti, in order to understand the diffusion process for technical pure materials. In further investigations AA5xxx and AA6xxx are joined with cp-titanium (T<550C), in order to evidence the effect of alloying elements. The joints are evaluated by optical as well as SE-microscopy. EDX-analysis allows the definition of the diffusion zone as well as the composition. Comparable investigations when joining aluminium to magnesium are reported as well. Selected results upon mechanical behaviour of joints will be reported too, and confirm the suitability of the process for high strength applications.

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