From macro-, through meso- to micro-scale: Densification behavior, deformation response and microstructural evolution of selective laser melted Mg-RE alloy

• Densification of SLM Mg-RE alloy was affected by laser input from conduction to keyhole mode. • 2 VPSC proves that deformation of SLM Mg-RE alloy was governed by the basal and prismatic slips. • Precipitation hardening is the primary mechanism driving the mechanical improvement of SLM Mg-RE alloy. To clarify the densification behavior, deformation response and strengthening mechanisms of selective laser melted (SLM) Mg-RE alloys, this study systematically investigates a representative WE43 alloy via advanced material characterization techniques. A suitable laser output mode fell into the transition mode, allowing for the fabrication of nearly full-density samples (porosity = 0.85 ± 0.021%) with favorable…