Conventional fusion welding of stainless steel in automotive underbody structures often introduces crevices, heat-affected microstructural heterogeneity, and, in some cases, galvanic couples that accelerate corrosion in chloride-rich environments. Transient liquid phase bonding (TLPB) offers an attractive alternative, but industrial implementation requires vacuum furnaces and carefully controlled pressure, limiting adoption for high-throughput, cost-sensitive applications. This work will evaluate a deliberately simplified TLPB process—performed in a conventional air furnace with intermittent manual pressing—as a practical, corrosion-resilient alternative to conventional welds for 304 stainless steel components exposed to simulated deicing salt. Sheets of 304 stainless steel will be joined using (i) conventional fusion welding and (ii) simplified TLPB with copper and nickel interlayers. The TLPB process parameters (bonding temperature, dwell time, and pressing schedule) will consider the diffusion homogenization, reflecting realistic shop-floor constraints. Resulting joints will be characterized using high resolution characterization techniques, such as optical microscopy, scanning electron microscopy with energy-dispersive spectroscopy, and 3D microscopy to elucidate the multiphase features of the anode-cathode distribution. Corrosion performance will be assessed using a multi-technique approach via accelerated salt spray and electrochemical testing to quantify susceptibility to localized attack. For both welds and TLPB joints, local techniques such as Scanning vibrating electrode technique (SVET) will map anodic and cathodic activity. This work will guide us to understand the failure mechanisms prevailing during service life. The paper will deliver processing–microstructure–corrosion relationships, screening parameters, and design guidelines for corrosion assessment of simplified TLPB for stainless structures exposed to aggressive service environments.
