Fundamental review on gas tungsten arc welding of magnesium alloys: challenges, innovations, and future perspectives

This review paper explores the advancements and applications of gas tungsten arc welding (GTAW) for magnesium alloys, which are increasingly utilized in aerospace, automotive, and biomedical industries due to their high strength-to-weight ratio and excellent corrosion resistance. However, welding magnesium alloys presents significant challenges, including high reactivity with oxygen and hydrogen, hot cracking, porosity, and thermal distortion. While conventional GTAW methods provide satisfactory results, they often fall short in meeting the stringent requirements of high-precision applications. Recent innovations, such as pulse-modified and hybrid GTAW techniques, show great promise in addressing these challenges by improving heat input control, reducing defect formation, and enhancing mechanical properties. Key factors such as the choice of shielding gas, filler materials, and heat input control are critical for ensuring high-quality welds. Furthermore, advancements in artificial intelligence, real-time monitoring, and automation are poised to enhance the accuracy and efficiency of GTAW, making it a more reliable option for industrial applications. The paper also highlights future trends, including the integration of GTAW with additive manufacturing, which could expand its use in renewable energy, biomedical implants, and lightweight structures. This review demonstrates the transformative potential of GTAW for advancing the use of magnesium alloys in various high-performance industries.