Forming and Preparation of Mg/Al Alloy Composites: Advantages, Challenges and Breakthrough Directions

XIE Xufeng; ZHOU Yisong; ZHAO Jianxing; WANG Yan; ZHONG Tao; HU Hongjun; MA Xiang

doi:10.3969/j.issn.1674-6457.2025.10.001

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Journal of Netshape Forming Engineering ›› 2025, Vol. 17 ›› Issue (10) : 1-20. DOI: 10.3969/j.issn.1674-6457.2025.10.001

Light Alloy Forming

Forming and Preparation of Mg/Al Alloy Composites: Advantages, Challenges and Breakthrough Directions

XIE Xufeng¹, ZHOU Yisong¹, ZHAO Jianxing¹, WANG Yan¹, ZHONG Tao^2,*, HU Hongjun¹, MA Xiang³

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Abstract

Lightweight technology plays an important role in promoting energy conservation and emission reduction in the transportation industry, and bimetallic composite materials have enormous potential in this field. Among them, Mg/Al composite materials have attracted much attention due to the unique advantages of magnesium alloys and aluminum alloys, but there is a problem of the effect of hard and brittle intermetallic compounds on the bonding strength, and improving their bonding strength has become a research hotspot. The work aims to review the research progress on the preparation methods of Mg/Al composite materials in China and abroad, including welding, casting, rolling, and extrusion and point out that the diffusion layer structure and the formation effect of intermetallic compounds will vary under different processes. To improve the bonding strength, the focus is placed on adding alloying elements and optimizing processes. Adding alloying elements such as Zn, Ni, Ag, etc. can effectively improve the mechanical properties of the matrix under various connection processes, but may also introduce new problems such as reduced hardness, stress concentration, and decreased fracture toughness. In terms of process optimization, ultrasonic vibration assisted technology has shown significant advantages in welding and casting, which can refine grains, suppress the growth of intermetallic compounds, optimize interface structure, and improve the shear strength, hardness, and toughness of materials. However, there is relatively little research on extrusion technology. In addition, the positive effects of ultrasonic vibration on the microstructure and mechanical properties of Mg and Al alloys are summarized, the challenges currently faced by ultrasonic vibration assisted technology are pointed out, and the optimization direction and development prospects are put forward.

Key words

Mg/Al composite materials / lightweight technology / ultrasonic vibration assisted / extrusion shear process / bonding strength

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XIE Xufeng, ZHOU Yisong, ZHAO Jianxing, WANG Yan, ZHONG Tao, HU Hongjun, MA Xiang. Forming and Preparation of Mg/Al Alloy Composites: Advantages, Challenges and Breakthrough Directions[J]. Journal of Netshape Forming Engineering. 2025, 17(10): 1-20 https://doi.org/10.3969/j.issn.1674-6457.2025.10.001

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Funding

Major Project of Science and Technology Research Project of Chongqing Municipal Education Commission (KJZD-M202501105); Project of Enhancing the Basic Ability of Scientific Rescarch of Young and Middle-aged Teachers in Guangxi Colleges and Universities (2025KY1333)