In the present investigation, a dissimilar metal joint between Titanium alloy (Ti6Al4V, ELI) and pure Aluminium (Al) was achieved using an Al-Si based filler alloy by vacuum brazing technique. A sound dissimilar joint of Ti to Al was achieved after a series of pilot experiments with overlap configuration. A thin foil of 0.2 mm thick Al-Si was used as filler alloy. With an overlap of 7.5 mm, the average joint strength achieved was 64 MPa. Mechanical properties were evaluated by varying the overlaps of the vacuum brazed joints and then compared. The average joint strength achieved for an overlap distance of 3, 6 and 9 mm were 57 ± 0.5, 53 ± 0.5 and 59 ± 0.5 MPa, respectively. The brazed joints were investigated for macrostructure, microstructure, scanning electron microscope and electron probe micro analyser analysis for characterization studies.
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