Welding of magnesium alloys is an emerging technology for structural applications, Laser beam welding (LBW) as a highly automated process enables the welding of complex geometrical forms in terms of strength, mechanical stiffness, production velocity, and visual quality [1]. The challenge in developing the LBW process is not only to achieve a defect-free joining zone but also to achieve the required mechanical properties, which are influenced by the sheet metal properties and the welding equipment as well as process parameters used. Line welding for crash worthiness of AZ31 and ZEK100 was tested in [2], and spot welding for structural applications in [3]. Wobbling techniques stand for a high gap-bridging capacity and high surface quality [4]. This means that edge preparation does not have to be perfect and certain geometrical offsets can be compensated for.

Greater efforts need to be taken care of when high-speed welding of AZ31 in combination with a small focus diameter leads to thin weld seams with superior deformation capacity, caused by a micro-texture evolution in the weld seam resembling the base material [5]. Mechanical properties in terms of fatigue, fatigue crack propagation, and fracture mechanics behaviour are topics of on-going research.

Due to the attractiveness of 3D printing, solutions for Mg alloys are the focus of research activities. Due to problems in the handling of magnesium powders, laser metal deposition by wire (LMD-wire) might be an easier way to generate structural parts. Of course, the spatial resolution of powder bed processes cannot be achieved with conventional welding wires. Therefore, newly drawn magnesium wires were tested for their processability. Macro and microsections, hardness values, and mapping of the main alloying elements are compared for the different alloy systems [6].