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Mg-Al joining is problematic due to dissimilar high-temperature flow characteristics that often result in defects and brittle intermetallic compounds (IMC) at the interface. Process development on lap joining of 1.27 mm 6022 (top sheet) and 1.5 mm ZEK100 (bottom sheet) intended for an automotive door application is presented. Process development was conducted in linear welding using power control (modulating torque and spindle speed) with multiple tool designs and welding parameters. Process variables were correlated to micro- and macro-structure and mechanical properties. A 2D computational model was created to understand the failure mechanism and contribution of mechanical interlocking towards joint strength. Joint efficiency of 48% (compared to base 6022 Al) at a welding speed of 0.625 m/min has been demonstrated thus far. For a thin (<2 mm) automotive sheet with a softer material as a …