A novel process named Expansion Equal Channel Angular Pressing (Exp-ECAP) which couples multiple forms of deformation such as upsetting, shearing, and extrusion into one was proposed. Ti/Al bimetallic composite rod was successfully fabricated by a single pass of Exp-ECAP process at 450 ℃ combined with post annealing heat treatment. The interface microstructure and bonding properties of Ti/Al bimetallic composite rod were investigated using SEM, EDS, XRD, EBSD and shear test. The results show that under the severe shear stress of Exp-ECAP process and the high-temperature annealing conditions, the Ti/Al bimetallic composite rod achieves good interfacial bonding quality, and a metallurgical bonding layer of approximately 1.27μm thickness is appeared through mutual diffusion of the titanium and aluminum matrix elements. New phases generated in the bonding interface layer are mainly intermetallic compound TiAl, and a small amount of inhomogeneous distributed Ti3Al (near the titanium side) and TiAl3 (near the aluminum side) are also contained. Moreover, a large number of equiaxed ultrafine grains are obtained in the Ti/Al interface bonding layer through phase transformation reactions and partial recrystallization, and the grains grow randomly without obvious preferred orientation. The shear strength of Ti/Al bimetallic composite rod is about 66.29 MPa, and shear failure mainly occurs in the TiAl phase layer, exhibiting brittle fracture characteristics.