Welding Techniques for Magnesium Alloy Joints: A Comprehensive Review

Magnesium (Mg) alloys are crucial for lightweight automotive design, underscoring the need for effective welding despite their poor weldability and susceptibility to defects such as cracks. The paper was prepared by reviewing available scientific databases of studies and patents using appropriate keywords. It reviews the properties, applications, and welding methods (fusion, friction, diffusion, explosive, and hybrid) of Mg alloys, assessing their advantages, disadvantages, and precautions. The importance of understanding the mechanical behavior and structural integrity of welded joints was highlighted. The impact of process variables on weld microstructure and properties, along with future research areas, is also addressed. AZ-series Mg alloys were found to be favored for weldability. For them, primary welding methods include GTAW, GMAW, LBW, and FSW. Trends emphasize solid-state techniques, advanced dissimilar metal joining, and AI optimization to enhance welding efficiency and quality. Welding of modern Mg-inclusive high-entropy alloys is under intensive development.