The Paton Welding Journal, 2026, №06

2026 №06 (04)

DOI of Article 10.37434/tpwj2026.06.05

2026 №06 (06)

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The Paton Welding Journal, 2026, #6, 41-48 pages

Joining aluminum and magnesium alloys by diffusion welding (Review)

L.V. Petrushynets¹, V.E. Fedorchuk¹, Yu.V. Falchenko¹, O.O. Novomlynets²

¹E.O. Paton Electric Welding Institute of the NASU. 11 Kazymyr Malevych Str., 03150, Kyiv, Ukraine. E-mail: moremia2@ukr.net
²National University “Chernihiv Polytechnic” 95 Shevchenko Str., 14030, Chernihiv, Ukraine

Abstract
Magnesium alloys, due to their low density and high specific strength, are promising materials for mechanical engineering, the automotive industry, and portable electronics. However, their wider application is limited by low strength and thermal stability, as well as a high susceptibility to corrosion of this group of materials. The widespread use of magnesium alloys often requires reliable bonding with other materials, primarily aluminum alloys. However, obtaining such bonds is technologically challenging due to the significant difference in the physicochemical properties of these two materials, which leads to the formation of brittle phases and degradation of mechanical properties. This paper considers the potential of utilizing various technological approaches to joining aluminum and magnesium by diffusion welding. It has been demonstrated that welding magnesium alloys to aluminum without interlayers leads to significant scatter in joint strength values, which is caused by considerable differences in the welding parameters (temperature, pressure, and process duration) used by the authors of the publications. The use of interlayers such as Cu, Zn, Ag, Ni, and Sn + Zn significantly affects the microstructure, phase composition, and mechanical properties of the joints, which is associated with the varying tendency of these metals to form intermetallic phases at the interface. The highest shear strength of 76.8 MPa was obtained when using an Sn + Zn interlayer. However, this technological process is highly sensitive to fluctuations in the welding temperature, which is due to changes in the amount of liquid phase formed between magnesium and aluminum and, consequently, in the phase composition of the joint interface. Thus, the diffusion welding of magnesium alloys to aluminum remains a challenging problem that requires further investigation.
Keywords: diffusion welding, magnesium alloy, aluminum alloy, interlayer, microstructure, strength

Received: 14.10.2025
Received in revised form: 12.12.2025
Accepted: 23.06.2026

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Suggested Citation

L.V. Petrushynets, V.E. Fedorchuk, Yu.V. Falchenko, O.O. Novomlynets (2026) Joining aluminum and magnesium alloys by diffusion welding (Review). The Paton Welding J., 06, 41-48. https://doi.org/10.37434/tpwj2026.06.05

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