<p>Through pulse current-assisted forming technology integrated with stretch-stamping characteristics, this study leveraged a self-developed pulsed current tribometer to investigate the friction coefficient evolution between AZ31B magnesium alloy and P20 steel under pulsed current densities (0–20 A/mm²). A high-accuracy variable friction model was established. Experimental results demonstrate that at 0–12 A/mm², a dense oxide film forms on the AZ31B surface, reducing the average friction coefficient from 0.3694 to 0.1471 with increasing current density. Conversely, at 12–20 A/mm², the friction coefficient increases to an average of 0.4483. Pulsed current induced solidification-driven formation of β-phase Mg₁₇Al₁₂ within the sheet. Grain size initially decreased, then increased, while dislocation density across all crystallographic planes progressively reduced, reaching a minimum of 0.29 × 10^–12 m². Comprehensive observations identified 12 A/mm² as optimal for enhancing formability. Finite element simulations comparing the developed variable friction model and ABAQUS’s built-in constant friction model were validated against experimental results, confirming both the accuracy of the variable model and the efficacy of electro-assisted forming in improving magnesium alloy formability.</p> Graphical Abstract <p></p>