The aluminum joints were prepared by overcasting liquid aluminum A356 onto 6101 aluminum extrusion bars. The microstructure, element distribution, hardness and tensile strength of the joint interface area were investigated, the mechanism of interface formation and fracture behavior were analyzed. The results show that good metallurgical bonding was formed in the joints by electro-plating the solid 6101 aluminum alloy with a layer of zinc coating and carefully controlling the overcasting process. There is a transition zone between the two bonded aluminum alloys, and the fine equiaxed grained structure in the transition zone is due to the high undercooling during solidification. The tensile strength of the joint interface is higher than that of the as-cast A356 aluminum alloy(about 145 MPa) and the final fracture is always located in the as-cast A356 material.
