TIG is the most popular process for welding magnesium and magnesium alloys.

The
major alloying elements used with magnesium are aluminum, zinc, and thorium. Most
magnesium alloys are weldable with this process, but the weldability will vary with
the alloy . Table 9-16 shows the main alloying elements used and the relative
weldability of the alloys. The rating is based mainly on the susceptibility to
cracking. Aluminum content up to about 10% helps the weldability because it
promotes grain size refinement, and zinc content above about 1% will increase the
tendency towards hot cracking. Alloys that have a high zinc content are very
susceptible to cracking and have poorer weldability. Thorium alloys generally have
excellent weldability. Magnesium forms an oxide similar to aluminum oxide, which
gives these two metals similar welding characteristics. Alternating current is used
for most magnesium and magnesium alloy welding applications because of its good
oxide cleaning action, which allows higher welding speeds. Direct current electrode
positive is often used for welding metal thicknesses from less than 3/16 inch (4.8
mm) up to 3/8 inch (4.8 mm). Above this thickness, gas metal arc welding is often
used.Inert gases such as argon, argon-helium mixtures, and helium are required for
shielding because magnesium will react chemically with an active gas. Preheating is
often used on thin sections and on highly restrained joints to prevent weld
cracking. Thicker NAVEDTRA 14250A9-52
sections generally do not require preheating unless there is a high degree of joint
restraint. All of the different types of tungsten electrodes are used, especially
the pure and zirconium tungsten electrodes.Filler metal for the gas tungsten arc
welding of magnesium and magnesium alloys generally is one of four different types.
Filler metals with lower melting points and wider freezing ranges than the base
metal are often used to avoid cracking. Table 9-17 also shows a filler metal
selection chart. The type of filler metal used is governed by the chemical
composition of the base metal.MagnesiumMajor
AlloyingWeldabilityFillerAlloyElementsRatingMetalWrought AlloysAZ10AAluminum
Zinc1AZ61A AZ92AAZ31BAluminum Zinc1AZ61A AZ92AAZ31CAluminum Zinc1AZ61A
AZ92AAZ61AAluminum Zinc2AZ61A AZ92AAZ80AAluminum Zinc2AZ61A AZ92AHK31AThorium
Zirconium1EZ33AHM21AThorium Manganese1EZ33AHM31AThorium
Manganese1EZ33ALA141ALithium Aluminum2LA141A EZ33AM1AManganese1AZ61A AZ92AZE10AZinc
Rare Earths1AZ61A AZ92AZK21AZinc Zirconium2AZ61A AZ92AZK60AZinc Zirconium4EZ33ACast
AlloysAM100AAluminum Manganese2AZ101A AZ92AAZ63AAluminum Zinc3AZ101A
AZ92AAZ81AAluminum Zinc2AZ101A AZ92AAZ91CAluminum Zinc2AZ101A AZ92AAZ92AAluminum
Zinc2AZ101AEK41ARare Earths Zirconium2EZ33AEZ33ARare Earths Zinc1EZ33AHK31AThorium
Zirconium2EZ33AHZ32AThorium Zinc2EZ33AK1AZirconium1EZ33AQE22ASilver Rare
Earths2EZ33AZE41AZinc Rare Earths2EZ33AZH62AZinc Thorium3EZ33AZK51AZinc
Zirconium4EZ33AZK61AZinc Zirconium4EZ33ATable 9-16 � Magnesium alloy
classification, weldability and filler selection(1=excellent, 2=good, 3=fair, 4
=poor).NAVEDTRA 14250A9-53