Interfacial engineering of solid-state-processed Mg/Al laminated composites: A review

Mg/Al laminated composites are promising lightweight structural materials because they combine the low density of Mg with the corrosion resistance, ductility, and formability of Al. Solid-state processing is particularly attractive for fabricating these laminates because it avoids bulk melting, reduces liquid-state defects, and offers more controllable interfacial evolution. However, their mechanical performance and service reliability are governed by the interfacial state generated during processing. A well-controlled interface promotes metallurgical bonding and load transfer, whereas excessive intermetallic compound (IMC) growth and defect accumulation accelerate embrittlement and premature failure. Despite extensive research, a unified framework linking thermal activation, mechanical deformation, interfacial evolution, and laminate performance remains lacking. This review examines Mg/Al laminates through a processing-regime framework that classifies representative solid-state routes according to the relative contributions of heat and deformation to interface formation. It then discusses sequential interfacial evolution, including oxide-film disruption, intimate contact, atomic interdiffusion, IMC formation, and defect development, and evaluates how interfacial states affect tensile response, failure, formability, and long-term reliability. Three interface-tailoring strategies are critically assessed: kinetic control of interfacial reactions, structural reshaping and mechanical compatibility design, and interlayer introduction. Literature data are synthesized to identify cross-study process–interface–property trends. Finally, this review highlights the need for quantitative process–interface maps, crystal-plasticity-enabled multiscale modeling, damage-tolerant interfaces, integrated matrix–interface co-design, and long-term service validation, outlining an interface-centered design strategy for Mg/Al and other dissimilar-metal laminated composites.