Welding of magnesium alloys to steels: A review of metallurgical interactions, mechanical properties, and process control

Magnesium alloys support eco-friendliness, efficiency in energy and foster economic models for design sustainability and innovation. Magnesium alloys are extensively employed in the production of lightweight automotive aerospace components. The utilization of lightweight alloys in structures is a key aspect for advanced aerospace and automotive manufacture, with a focus on welding methods. Multi-material structures made of magnesium, titanium, steel, and aluminium alloys are efficient for achieving lightweight safety and low cost. Mg alloys show poor welding ability with other materials because of their chemical and physical properties, leading to cracks and other defects during the welding process. This study aims to provide a comprehensive review on the effect of processes and process variables on microstructure and mechanical properties in welding of magnesium alloys with steels. This study also presents the strategies and advanced welding techniques developed by various researchers that overcome the challenges and also enhance the weldability with defect-free weld joints. This study also highlighted the application of artificial intelligence for monitoring as well as controlling the welding process for the production of high-quality weld joints.