First 3D X-ray views of magnesium could transform car manufacturing

University of Michigan researchers have achieved the first-ever 3D X-ray imaging of microscopic structures inside magnesium alloys, revealing how these lightweight metals absorb mechanical stress without fracturing. Using advanced dark-field X-ray microscopy at the European Synchrotron Radiation Facility, the team visualized the formation and evolution of “deformation twins”—mirror-image crystal regions that increase magnesium’s ductility but can also lead to defects and cracks. Their experiments showed that all three types of twins form at triple junctions where three crystals meet, with defects consistently appearing where twins contact other crystals. This insight into magnesium’s stress response is crucial for optimizing its durability in automotive applications. Magnesium alloys, being 30% lighter than aluminum, hold promise for making cars stronger, lighter, and more fuel-efficient, but their broader use has been limited by unpredictable behavior under strain. The study, funded by the U.S. Department of Energy and published in Science, provides a detailed understanding of magnesium’s crystalline slip systems and twinning mechanisms