Challenges and opportunities in the production of magnesium parts by directed energy deposition processes

Mg-alloys have gained considerable attention in recent years for their outstanding properties such as lightweight, high specific strength, and corrosion resistance, making them attractive for applications in medical, aerospace, automotive, and other transport industries. However, their widespread application is hindered by their low formability at room temperature due to limited slip systems. Cast Mg-alloys have low mechanical properties due to the presence of casting defects such as porosity and anisotropy in addition to the high scrap. While casting methods benefit from established process optimization techniques for these problems, additive manufacturing methods are increasingly replacing casting methods in…