The　traditional　steel/lead　bonding　structures　are　based　on　bonding　process,　which　can　lead　to　serious　problems　in　the　application　and　long-term　storage,　such　as　local　strap　debonding,　aging　and　strength　degradation.　The　above-mentioned　problems　seriously　affect　the　integrity,　long-term　stability　and　environmental　adaptability　of　steel/lead　composite　structures.　This　paper　puts　forward　a　novel　additive　manufacturing　me-thod　to　fabricate　45　steel/lead　alloy　bimetallic　structures　by　direct　metallurgical　connection,　which　is　a　combination　of　droplet　deposition　manufacturing　and　variable-polarity　TIG　arc　process.　The　microstructure　and　mechanical　properties　of　the　fabricated　samples　were　analyzed　by　using　many　experimental　means　such　as　OM,　SEM,　EDS,　microhardness　test,　and　so　on.　The　results　showed　that　a　nonlinear　relationship　existed　between　the　heat　input　of　the　welding　arc　and　the　feature　sizes　(deposition　height　and　width)　of　the　lead　alloy　deposited　layers.　No　evidence　of　cracks　and　micro　voids　was　found　at　the　bonding　interface.　The　thickness　of　the　interfacial　reaction　layer　is　within　the　range　of　30-70　μm.　The　average　interfacial　bonding　strength　of　the　fabricated　sample　can　reach　28.4　MPa,　which　is　much　higher　than　4.2　MPa　of　the　report.　The　fracture　location　is　always　on　the　side　of　lead　alloy　deposited　layers.　©　2022,　Materials　Review　Magazine.　All　right　reserved.