Abstract: Cu/Al joints are widely applied in power electronic industry.However, brittle fracture occurs in the Cu/Al joints during long-term service, which seriously deteriorates the service safety.Zn-based solders were designed, and the properties were analyzed and optimal solder composition was obtained.The copper plate surface was modified by electroless Ni-P plating, and the Cu/Al lap brazing tests were carried out by using induction brazing and the optimal solder.The results show that increasing the Al content in the Zn-based brazing material and adding a certain amount of Cu, Ag and rare earth elements can enhance the wettability, strength and corrosion resistance of the brazing material.The nickel-phosphorus coating significantly improves the wetting performance of the Zn-based brazing material on the copper plate, changes the interface reaction of the copper-aluminum joints, and significantly refines the weld grain.The mechanical properties of the Cu/Al joint obtained using the optimized Zn-based brazing material and the electroless Ni-P plating process are significantly improved, the shear strength reaches 37 MPa and the fatigue life reaches 85000 times.