The addition of titanium powder and physical vapor deposition of titanium were applied for metallization of zirconia surface. The hybrid members of stabilized ZrO2/Ti–6Al–4V were fabricated using the Ag–28Cu filler metal. Different phases including TiCu3, Ti3Cu3O, Ti2Cu, and Ti6O were observed in the microstructure of joints. The sound joints were obtained when physical vapor deposition method was used for metallization; while various defects were observed after addition of the metallic powder to the joint. The increased thickness of filler metal or the metallized layer of zirconia promoted formation of the interaction layer between ceramic and filler metal. The formation of Ti3Cu3O along the joint interface encouraged the brittle fracture and decreased strength of the dissimilar joint. The maximum shear strength of the joint was obtained for the specimen which was metallized for 6 min by the physical vapor deposition method and was joined using the 50 μm thick filler metal.

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