Higher　shear　strength　and　fusion　line　failure　were　measured　in　CMT　brazed　lap　joint　of　aluminum　alloy　6061　and　zinc　coated　steels　with　high　strength　(DP600)　or　thick　plate　(1.2　mm).　Lower　shear　strength　and　interface　failure　were　observed　only　if　aluminum　was　brazed　with　low　strength　(270　MPa)　and　thin　steel　sheet　(0.7　mm).　A　numerical　model　was　developed　for　the　prediction　of　shear　strength　and　failure　modes　of　the　CMT　lap　joints.　The　maximum　principle　stress　and　deformation　energy　at　the　interface　layer　of　the　CMT　joints　were　adopted　as　failure　criteria　for　interface　failure　prediction.　The　equivalent　plastic　strain　in　the　weld　metal,　HAZ　and　base　metal　of　aluminum　side　of　the　CMT　brazed　joints　was　used　as　a　criterion　for　failure　prediction　occurred　on　the　fusion　line.　The　shear　strength　of　CMT　joints　and　the　two　failure　modes　can　be　accurately　estimated　by　the　developed　numerical　model.　(c)　2013　Elsevier　B.V.　All　rights　reserved.