The mechanical properties of dissimilar metal joints are strongly related to the brittle intermetallic compounds (IMCs) that form at the weld interfaces. In this study, the effects of temperature, local composition and plastic strain on the formation mechanism of IMCs in a welded joint between 6061 Al and AZ31 Mg were investigated. The results demonstrate that Al3Mg2 is formed when the strain rate reaches 10 s−1, even though the temperature is lower than the Al–Mg eutectic temperature, which suggests that plastic deformation may accelerate the formation of IMCs in the deformation zone. Meanwhile, the formation of Al–Mg IMCs can be suppressed by Mg–Zn and Al–Mg–Zn compounds when Zn filler is added at the Al/Mg interfaces.
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