The microstructure evolution of a Mg–Gd–Y alloy was studied using uniaxial tension combined with an electron backscatter diffraction technique. The results show that large amounts of slip transfer phenomena can be observed around the grain–boundary area after tension, and the activation of these slips depends largely on the misorientation of grain boundaries. The Mg–Gd–Y alloy shows almost randomized grain–boundary misorientation, but transferred slip traces were preferred at boundaries with misorientation around the [0001] axis between 0–30°. Theoretically, materials with a higher fraction of slip transfer at the grain–boundary area would improve the ductility. Upon comparing the two groups of magnesium alloy with different grain–boundary misorientation distributions, the one with more grain boundaries favored for slip transfer achieved higher elongation during a tension test. Therefore, in addition to weakening the texture, adjusting the misorientation of the grain boundaries appears to be a new method to improve the ductility of magnesium alloys.

Extruded Mg-Gd-Y alloy tubes were obtained by using cast ingot and extruded bar billets. Microstructure and mechanical properties were also studied with two different cooling methods: air cooling and water cooling. The result shows that by using an extruded bar as billet extruded tubes achieves higher elongation comparing to using cast ingots due to favored texture for the activation of basal slip. Using the water-cooling method, extruded tubes achieve a higher yield strength compared to the air cooling method due to their fine grain size. Using cast ingot billets and the water-cooling method, the elongation is only 6% due to large unrecrystallized grains caused by inhomogeneous deformation and unfavored texture for the activation of basal slip. Using the extruded bar billet and the water-cooling method, the tube has uniformed small grains and much more randomized texture caused by the inhibition of preferred grain growth process. The highest texture intensity is only 1.852 in this kind of tube. Both high yield strength (195.3 MPa) and high elongation (23.9%) are achieved in this tube.

The intergranular cracking in the Mg-Gd-Y alloy was investigated by an in situ tension test combined with an electron backscattered diffraction (EBSD) measurement and digital image correlation (DIC). During the tension test, the crack was found at the triangle point of the grain boundary area with profuse slip traces. DIC results show that inhomogeneous strain distribution can be found at the triangle point area, leads to serious deformation incompatibility at this point. This also leads to a weak point for crack initiation, and as tension strain increases, the crack would extend from the weak point along the grain boundary.