The microstructure evolution and microhardness of Fe–Mn–Al–C steel heat-affected zone (HAZ) were investigated systematically using the weld thermal simulation technique. The results illustrated that the microstructure in HAZ with different peak temperatures (600, 800, 1000 and 1300°C) and heat inputs (10, 20 and 30 kJ cm–1) mainly consisted of ferrite and austenite. When the peak temperature was 1300°C, there are many high-angle grain boundaries which may inhibit crack propagation. With the increase in heat input, κappa carbide precipitation increased, the grain size became finer and microhardness increased. The microhardness was 438 HV when the peak temperature was 1300°C at 30 kJ cm–1. Highlights The welding of high carbon, high aluminium and low-density steel was simulated. The HAZ was composed of austenite and a small amount of high-temperature δ-ferrite. The proportion of high- and low-angle grain boundaries has a great influence on the mechanical properties. The welding heat input was 30 kJ cm–1, the grain size of the HAZ decreased and microhardness was the largest.