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Abstract Understanding and controlling the development of deformation twins is paramount for engineering strong and stable hexagonal close-packed (HCP) Mg alloys. Actual twins are often irregular in boundary morphology and twin crystallography, deviating from the classical picture commonly used in theory and simulation. In this work, the elastic strains and stresses around irregular twins are examined both experimentally and computationally to gain insight into how twins develop and the microstructural features that influence their development. A nanoprecession electron diffraction (N-PED) technique is used to measure the elastic strains within and around a $$\left\{ {10\overline{1}2} \right\}$$ 10 1 ¯ 2 tensile twin in AZ31B Mg alloy with nm scale resolution. A full-field elasto-viscoplastic fast Fourier transform (EVP-FFT) crystal plasticity model of the same sub-grain and irregular twin structure is employed to understand and interpret the measured elastic strain fields. The calculations predict spatially resolved elastic strain fields in good agreement with the measurement, as well as all the stress components and the dislocation density fields generated by the twin, which are not easily obtainable from the experiment. The model calculations find that neighboring twins, several twin thicknesses apart, have little influence on the twin-tip micromechanical fields. Furthermore, this work reveals that irregularity in the twin-tip shape has a negligible effect on the development of the elastic strains around and inside the twin. Importantly, the major contributor to these micromechanical fields is the alignment of the twinning shear direction with the twin boundary. 

The {-1012} tensile twins terminating inside the grains of a deformed Mg-Y alloy were investigated by transmission electron microscopy. The crystallographic features of terminating twins and associated slip structures were quantified and correlated. The local stresses developed at a terminating {-1012} twin were computed using crystal plasticity simulations in order to interpret the observed slip patterns. Results indicate that both basal and matrix glide were involved in accommodating the plastic stresses developed in the vicinity of terminating twins. Along the twin boundary, the defect contrast consistent with that of lattice dislocations and twinning partials was observed. Based on these observations, a dislocation reaction is proposed that establishes an interrelationship between the observed matrix glide and {-1012} twinning in Mg-Y alloys. 

Deformation twinning is a prevalent mode of plastic deformation in hexagonal close packed (HCP) magnesium. Twin domains are associated with significant lattice reorientation and localized shear. The theoretical misorientation angle for the most common 1012 tensile twin in magnesium is 86.3°. Through electron backscatter diffraction characterization of twinning microstructure, we show that the twin boundary misorientation at the twin tips is approximately 85°, and it is close to the theoretical value only along the central part of the twin. The variations in twin/matrix misorientation along the twin boundary control the twin thickening process by affecting the nucleation, glide of twinning partials, and migration of twinning facets. To understand this observation, we employ a 3D crystal plasticity model with explicit twinning. The model successfully captures the experimentally observed misorientation variation, and it reveals that the twin boundary misorientation variations are governed by the local plasticity that accommodates the characteristic twin shear. 

Twins in hexagonal close-packed polycrystals, most often nucleate at grain-boundaries (GBs), propagate into the grain and terminate at opposing GBs. Regularly, multiple parallel twins of the same variant form inside the same grain. When twins terminate inside the grains, rather than the grain boundary, they tend to form a staggered structure. Whether a staggered twin structure or the more common grain spanning twin structure forms can greatly affect mechanical behavior. In this work, the underlying mechanism for the formation of staggered twins is studied using an elasto-visco-plastic fast Fourier transform model, which quantifies the local stresses associated with 1012-type staggered twins in magnesium for different configurations. The model results suggest that when a twin tip is close to the lateral side of another twin, the driving force for twin propagation is significantly reduced. As a result, the staggered twin structure forms. 

Recent advancements in the severe plastic deformation process called accumulative roll bonding (ARB) can help to address the long‐standing need for manufacturing lightweight, high‐strength Mg sheet materials. However, the fabrication of Mg alloy‐based laminates via ARB remains a challenge due to the intrinsically poor formability of Mg. Herein, it is shown that Mg‐based composite laminates with refined layers can be fabricated via several room‐temperature ARB cycles with appropriate intermediate annealing and alloy selection. The final laminates made here consist of equal volume fractions of a dilute Mg–Zn–Mn–Ca alloy phase and a pure Nb phase with fine 150 μm layer thicknesses. Deformation texture evolution in both phases within the composite is analyzed via neutron diffraction measurements taken at different stages in the process. The analysis suggests that the annealing step recrystallizes the Mg‐alloy phase. It is also shown that for both phases, the stabilized deformation textures within the composite correspond to the classic stable textures of the individual constituents. Polycrystal texture modeling implies that {10–12} <‐1011> extension twinning developed in the Mg alloy during rolling.