The pulsed electric current bonding method was adopted to join Al6061 and SS304 using an aluminium powder as the interlayer. Taguchi method was performed to optimise the bonding parameters. The decreasing sequence of factors affecting the shear strength of the joints is bonding temperature, surface treatment and holding time. The microstructural characterisation and shear fracture of the optimal joint have been further analysed. A uniform diffusion layer was formed at the Al/SS304 interface, and the high hardness value of the layer could be attributed to the formation of the intermetallic compounds. The most promising joint was obtained under the optimal parameter condition, and failure of the joint was caused inside the Al interlayer.
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