Metals are the backbone of manufacturing owing to their strength and formability. Compared to polymers they have high mass density. There is, however, one exception: magnesium. It has a density of only 1.7 g/cm³, making it the lightest structural material, 4.5 times lighter than steels, 1.7 times lighter than aluminum, and even slightly lighter than carbon fibers. Yet, the widespread use of magnesium is hampered by its intrinsic brittleness. While other metallic alloys have multiple dislocation slip systems, enabling their well-known ductility, the hexagonal lattice of magnesium offers insufficient modes of deformation, rendering it intrinsically brittle. We have developed a quantum-mechanically derived treasure map which screens solid solution combinations with electronic bonding, structure and volume descriptors for similarity to the ductile magnesium-rare earth alloys. Using this insight we synthesized a surprisingly simple, compositionally lean, low-cost and industry-compatible new alloy which is over 4 times more ductile and 40% stronger than pure magnesium. The alloy contains 1 wt.% aluminum and 0.1 wt.% calcium, two inexpensive elements which are compatible with downstream recycling constraints.

Selective laser melting is a promising powder-bed-based additive manufacturing technique for titanium alloys: near net-shaped metallic components can be produced with high resource-efficiency and cost savings

Mg is the most important lightweight engineering alloy enabling future weight-reduced and fuel-saving engineering solutions. Yet, Mg is soft. Long-period stacking ordered (LPSO) structures in Mg alloys have unique crystal structures, characterized by both complex chemical and stacking order. They are essential for strengthening of Mg alloys. The formation mechanism of these LPSO structures is still under discussion. Here we report that Y/Zn enriched Guinier-Preston (GP) zones observed in a lean Mg-Y-Zn model alloy are precursors of early stage LPSO structures. We provide evidence of a new type of phase transformation mechanism which comprises the diffusional formation of Y/Zn enriched GP zones and their subsequent shear transformation into LPSO building blocks. The mechanism constitutes a new type of coupled diffusional-displacive phase formation sequence which may also be applicable to other alloy systems.