The formation of intermetallic compounds (IMC) at the Al/Fe interface determined the mechanical property of steel-aluminum welded joint. To understand the interfacial microstructure evolution and relate diffusion mechanism of atoms cross the Al/Fe interface, the effect of welding parameters on the interfacial IMC was studied, and the molecular dynamics method (MD) was used to simulate the diffusion process of Al and Fe atoms. Four temperatures (950 K, 1000 K, 1050 K, and 1100 K) were selected in the simulation model. The interfacial IMC are distributed in a laminar pattern, and their physical phases are mainly composed of Fe₂Al₅, controlling the Al/Fe atomic ratio of 5:2 in the IMC configuration, the Embedded Atom Method (EAM) potential is used to describe the interactions between Al and Fe atoms. In the Al-Fe system IMC conformation, the mean square displacement and diffusion (MSD) coefficient of Al atoms at different temperatures were small, and the main diffusion path is the Al atoms across the IMC conformation into the Fe crystal structure. The diffusion in the IMC conformation was mainly along the direction perpendicular to the interface. The diffusion mechanisms were mainly vacancy diffusion and interstitial diffusion mechanisms.

The anode assembly, as a key component in the electrolytic aluminum process, is composed of steel claws and aluminum guide rods. The connection quality between the steel claws and guide rods directly affects the current conduction efficiency, energy consumption, and operational stability of equipment. Achieving high-quality joining between the aluminum alloy and steel has become a key process in the preparation of the anode assembly. To join the guide rods and steel claws, this work uses Cold Metal Transfer (CMT) technology to clad aluminum on the steel surface and employs machine vision to detect surface forming defects in the cladding layer. The influence of different currents on the interfacial microstructure and mechanical properties of aluminum alloy cladding on the steel surface was investigated. The results show that increasing the cladding current leads to an increase in the width of the fusion line and grain size and the formation of layered Fe₂Al₅ intermetallic compounds (IMCs) at the interface. As the current increases from 90 A to 110 A, the thickness of the Al-Fe IMC layer increases from 1.46 μm to 2.06 μm. When the current reaches 110 A, the thickness of the interfacial brittle phase is the largest, at 2 ± 0.5 μm. The interfacial region where aluminum and steel are fused has the highest hardness, and the tensile strength first increases and then decreases with the current. The highest tensile strength is 120.45 MPa at 100 A. All the fracture surfaces exhibit a brittle fracture.