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Abstract The abrupt occurrence of twinning when Mg is deformed leads to a highly anisotropic response, making it too unreliable for structural use and too unpredictable for observation. Here, we describe an in-situ transmission electron microscopy experiment on Mg crystals with strategically designed geometries for visualization of a long-proposed but unverified twinning mechanism. Combining with atomistic simulations and topological analysis, we conclude that twin nucleation occurs through a pure-shuffle mechanism that requires prismatic-basal transformations. Also, we verified a crystal geometry dependent twin growth mechanism, that is the early-stage growth associated with instability of plasticity flow, which can be dominated either by slower movement of prismatic-basal boundary steps, or by faster glide-shuffle along the twinning plane. The fundamental understanding of twinning provides a pathway to understand deformation from a scientific standpoint and the microstructure design principles to engineer metals with enhanced behavior from a technological standpoint. 

Twin–twin interactions (TTIs) take place when multiple twinning modes and/or twin variants are activated and interact with each other. Twin–twin junctions (TTJs) form and affect subsequent twinning/detwinning and dislocation slip, which is particularly important in determining mechanical behavior of hexagonal metals because twinning is one major deformation mode. Atomic-level study, including crystallographic analysis, transmission electronic microscopy (TEM), and molecular dynamics (MD) simulations, can provide insights into understanding the process of TTIs and structural characters associated with TTJs. Crystallographic analysis enables the classification of TTIs and the prediction of possible interfaces of twin–twin boundaries (TTBs), characters of boundary dislocations, and possible reactions of twinning dislocations and lattice dislocations at TTBs. MD simulations can explore the process of TTIs, microstructures of TTJs, atomic structures of TTBs, and stress fields associated with TTJs. The predictions based on crystallographic analysis and the findings from MD can be partially verified by TEM. More importantly, these results provide explanation for microstructural characters of TTJs and guidance for further TEM characterizations.