La thèse est centrée sur la modélisation de la physique du comportement d’un alliage binaire et l’implémentation du meilleur modèle mathématique pour simuler le changement de phase liquide solide en tenant compte de la vitesse de refroidissement, la vitesse de solidification, la ségrégation, la convection naturelle et la surfusion afin d’optimiser la capacité de stockage de chaleur d'un tel matériau. Dans le présent travail, les températures pour lesquelles le changement de phase s'opère sont estimées grâce aux diagrammes des phases et la méthodologie CALPHAD qui retraduisent les différentes phases d'un alliage binaire, y compris la transformation isotherme. Pour cela, la minimisation de l'énergie de Gibbs est résolue dans un code de calcul développé à cette occasion et aboutit à l'identification des phases stables du matériau. Pour un intervalle de température souhaite le code permet d'estimer rapidement la décharge de chaleur pour la composition de l'alliage sélectionné en équilibre ou hors équilibre. Dans la méthode proposée, la vitesse de refroidissement du système permet de calculer la vitesse de solidification. Puis,celle-ci établit la relation entre la cinétique globale et la macrostructure. Basé sur le modèle de non-équilibre local, qui dépend de la variation du coefficient de partition, le degré de surfusion est prédit à partir de la vitesse de refroidissement appliquée. Une étude bibliographique a été réalisée pour amener une comparaison numérique et assurer la capacité de notre méthode à reproduire le changement de phase, en incluant des phénomènes spécifiques tels que la surfusion et la recalescence. / Latent Heat Thermal Energy Storage (LHTES) shows high storage density compared to sensible thermal systems. For high temperature applications, the use of alloys as phase change materials presents many advantages. Principally, varying alloy composition allows controlling the storage\discharge of thermal energy through an expected temperature range (defined by the heat source), and the high thermal conductivity givessuitable heat transfer properties to the system that receives/supplies the energy. However, some systems need a specific temperature range to correctly operate. In such conditions, subcooling (also known as undercooling) and segregation are undesirable phenomena in alloys when they are used as PCM. In thepresent work, we propose a method to predict the latent heat release during phase transformation of a binaryalloy submitted to a controlled cooling rate, including subcooling, segregation and variation of composition.This thesis describes the physical models that apply when heat is released from such a material. We takeinto consideration the cooling rate applied to the PCM, the solidification velocity, convective phenomena,melting temperature and subcooling. In the present work, phase diagrams and the CALPHAD methodologyare used to determine the temperature range for phase change (or constant temperature value for isothermal transformation) by minimizing the Gibbs equilibrium energy. The Gibbs free energy minimization has been implemented in a homemade numerical code. The material can be screened with different compositions for equilibrium or off-equilibrium solidification allowing quick selection of the optimal material for the specific heatsource. In the proposed method, the solidification velocity is obtained from the cooling rate. Then, variationin microstructure is driven by the solidification velocity using the local non-equilibrium diffusion model. Based on the local nonequilibrium model that depends on the partition coefficient variation, the subcooling degree, wich is derived from the applied cooling rate is predicted. A bibliographic study has been carried out and anumerical comparison has been undertaken to ensure the capacity of our code to reproduce the phase change of various materials that include phenomena such as subcooling and recalescence. The results highlight that the cooling rate is one of the most important parameters in the performance of the thermal storage, having a large effect on segregation and subcooling degree. Moreover, we show the influence ofpartition coefficient on the time evolution of solid fraction, considering a constant or a composition-dependent value. We can conclude that the latent heat release can be correctly predicted provided that the method correctly predicts the phase diagram and the variable partition coefficient. This work helps to accelerate the design and development of thermal storage systems and lays the foundation to continue exploring other kinds of materials (e.g. paraffins).

Au-dessus d'un taux de combustion seuil ≥ 7 at %, les produits de fission volatils Cs, I, et Te ou métalliques (Mo) sont partiellement relâchés hors du combustible et finissent par constituer une couche de composés de PF qui remplit progressivement le jeu existant entre la périphérie de la pastille et la surface interne de la gaine en acier inoxydable. Nous appelons cette couche JOG pour Joint Oxyde-Gaine. Mon sujet de thèse est axé sur l'étude thermodynamique du système (Cs, I, Te, Mo, O) + (U, Pu) ainsi que sur l'étude de la diffusion de ces produits de fission à travers le combustible vers le jeu combustible-gaine pour former le JOG.L'étude thermodynamique constitue la première étape de mon travail. Sur la base d'une analyse critique des données expérimentales issues de la littérature, les systèmes Cs-Te, Cs-I, Cs-Mo-O ont été modélisés par la méthode CALPHAD. En parallèle, une étude expérimentale a été entreprise pour valider la modélisation CALPHAD du système binaire Cs-Te. Dans une deuxième étape, les données thermodynamiques résultant de la modélisation CALPHAD ont été introduites dans la base de données du code de calcul thermodynamique ANGE (code interne au CEA dérivé du logiciel SOLGASMIX) dont la finalité est le calcul de la composition chimique du combustible irradié. Dans une troisième étape, le code de calcul thermodynamique ANGE (Advanced Numeric Gibbs Energy minimiser) a été couplé avec le code de simulation du comportement thermomécanique du combustible des RNR-Na GERMINAL V2. / For a burn-up higher than 7 at%, the volatile FP like Cs, I and Te or metallic (Mo) are partially released from the fuel pellet in order to form a layer of compounds between the outer surface of the fuel and the inner surface of the stainless cladding. This layer is called the JOG, french acronym for Joint-Oxyde-Gaine.My subject is focused on two topics: the thermodynamic study of the (Cs-I-Te-Mo-O) system and the migration of those FP towards the gap to form the JOG.The thermodynamic study was the first step of my work. On the basis of critical literature survey, the following systems have been optimized by the CALPHAD method: Cs-Te, Cs-I and Cs-Mo-O. In parallel, an experimental study is undertaken in order to validate our CALPHAD modelling of the Cs-Te system. In a second step, the thermodynamic data coming from the CALPHAD modelling have been introduced into the database that we use with the thermochemical computation code ANGE (CEA code derived from the SOLGASMIX software) in order to calculate the chemical composition of the irradiated fuel versus burn-up and temperature. In a third and last step, the thermochemical computation code ANGE (Advanced Numeric Gibbs Energy minimizer) has been coupled with the fuel performance code GERMINAL V2, which simulates the thermo-mechanical behavior of SFR fuel.

The aim of this work was to improve the heat capacity estimation of a material for usage within a CALPHAD-type assessment. An algorithm is derived that estimates the trend of heat capacity with temperature based on zero Kelvin properties and the thermal expansion coefficient at the Debye temperature. The algorithm predicts not only the trend of heat capacity but also the temperature trend of the volume and the bulk modulus, which can be also included in new thermodynamic databases. The algorithm is used to assess thermophysical properties of the intermetallic phases eta (Fe2Al5), epsilon~(Fe5Al8) and tau4 (FeAl3Si2). The heat capacity of the intermetallic phases zeta, eta, theta and epsilon of the Al-Fe system and of tau4 of the Al-Fe-Si system was measured using DSC. For the phases zeta, eta, and theta, a non-linearly increasing heat capacity approaching the melting temperature was observed. In addition, the heat capacity of three bcc-based Al-Fe samples including the B2-->A2 transition were determined. The Al-rich section of the Al-Fe phase diagram was studied using DTA and quenching experiments. The homogeneity ranges of the intermetallic phases were determined using SEM/WDS measurements. Based on own and literature values, a thermodynamic description of the Al-Fe system was assessed including the modelling of A2/B2 ordering and the homogeneity range of all intermetallic phases. In addition, thermodynamic parameters of the Al-Fe-Si, Al-Fe-Mg, and the Fe-Mg-Si system were assessed to obtain a thermodynamic description of the Al-rich side of the Al-Fe-Si-Mg system, which can be used to study phase transitions of typical A356-aluminium alloys.

[ES] La fabricación aditiva, de sus siglas en inglés AM (Additive Manufacturing) es un proceso que construye objetos sólidos tridimensionales mediante la superposicióon de materiales basados en un modelo de diseño asistido por ordenador. La AM está llamada a convertirse en la próxima revolución industrial, transformando el panorama del desarrollo y la producción. La AM ofrece numerosas ventajas, como posibilidades de diseño complejas y flexibles, la eliminación de procesos intermedios como el mecanizado, la independencia de los costes de producción del tamaño de los lotes, la reducción de los residuos de material, las estructuras ligeras, las reparaciones personalizadas de las máquinas y la capacidad de desarrollar nuevos materiales, entre otras ventajas. En las tecnologías de fabricación aditiva que emplean un rayo láser como fuente de energía, la materia prima inicial (en forma de polvo o cable) es fundida por la fuente de calor láser de forma controlada, capa a capa, hasta crear un componente con dimensiones finales o casi finales. Estas tecnologías implican someter el material impreso a un proceso térmico único, en el que el material se funde en un área muy específica y luego se enfría rápidamente a velocidades extremadamente altas de hasta 10^6 K/s. Por lo tanto, las microestructuras que surgen de los procesos de fabricación en AM difieren significativamente de las que se consiguen en los procesos tradicionales. Además, los materiales que se emplean principalmente en la AM no se han diseñado explícitamente para estas tecnologías. Las características específicas de los procesos de AM pueden utilizarse para lograr microestructuras y propiedades distintas en aceros que han sido adaptados para aprovechar las rápidas velocidades de enfriamiento y la historia térmica del proceso, entre otros factores. Por el momento, el número de calidades de acero comerciales disponibles en el mercado de la AM es limitado. Diversas industrias demandan nuevos grados de acero con menor densidad para disminuir el peso sin comprometer las propiedades mecánicas. Los aceros con alto contenido en manganeso se consideran materiales muy prometedores para aplicaciones estructurales debido a su excepcional combinación de resistencia y ductilidad, con una baja densidad. Sin embargo, a pesar de sus excepcionales propiedades, los aceros con alto contenido en manganeso se enfrentan a diversas limitaciones o retos durante las técnicas de procesado convencionales. Afortunadamente, la solidificación rápida puede resolver estos problemas. En este sentido, las tecnologías de AM basadas en láser proporcionan velocidades de enfriamiento rápidas, así como flexibilidad en términos de diseño geométrico. Los nuevos retos de estas tecnologías implicarán la microsegregación y el agrietamiento en caliente o hot cracking en inglés, que se producen durante la solidificación. Esta tesis está dedicada a explotar el método CALPHAD para realizar cálculos termodinámicos con el fin de diseñar varios aceros con alto contenido en manganeso que puedan prevenir eficazmente los problemas de solidificación rápida en AM. Las composiciones de acero diseñadas se produjeron en forma de polvo para AM mediante atomización con gas. Se analizaron los polvos para determinar su microestructura en relación con la química y la velocidad de enfriamiento. Ajustando adecuadamente los parámetros de impresión, estos polvos de acero con alto contenido en manganeso se imprimieron con éxito en AM, dando lugar a densidades relativas superiores al 99.9%. Se analizó la microestructura de estas muestras totalmente densas y se comparó con sus respectivos polvos, con el fin de identificar cualquier diferencia resultante de las variaciones en la velocidad de enfriamiento y los ciclos térmicos. Por último, tras definir el mejor conjunto de condiciones de impresión para cada composición de polvo, se produjeron varias muestras para evaluar las propiedades mecánicas. / [CA] La fabricació additiva, de les seues sigles en anglés AM (Additive Manufacturing) és un procés que construïx objectes sòlids tridimensionals mitjançant la superposició de materials basats en un model de disseny assistit per ordinador. L'AM està cridada a convertir-se en la pròxima revolució industrial, transformant el panorama del desenvolupament i la producció. L'AM oferix nombrosos avantatges, com a possibilitats de disseny complexes i flexibles, l'eliminació de processos intermedis com el mecanitzat, la independència dels costos de producció de la grandària dels lots, la reducció dels residus de material, les estructures lleugeres, les reparacions personalitzades de les màquines i la capacitat de desenvolupar nous materials, entre altres avantatges. En les tecnologies de fabricació additiva que empren un raig làser com a font d'energia, la matèria primera inicial (en forma de pols o filferro) és fosa per la font de calor làser de manera controlada, capa a capa, fins a crear un component amb dimensions finals o quasi finals. Estes tecnologies impliquen sotmetre el material imprés a un procés tèrmic únic, en el qual el material es funde en una àrea molt específica i després es refreda ràpidament a velocitats extremadament altes de fins a 10^6 K/s. Per tant, les microestructures que sorgixen dels processos de fabricació en AM diferixen significativament de les que s'aconseguixen en els processos tradicionals. A més, els materials que s'empren principalment en l'AM no s'han dissenyat explícitament per a estes tecnologies. Les característiques específiques dels processos d'AM poden utilitzar-se per a aconseguir microestructures i propietats diferents en acers que han sigut adaptats per a aprofitar les ràpides velocitats de refredament i la història tèrmica del procés, entre altres factors. De moment, el nombre de qualitats d'acer comercials disponibles en el mercat de l'AM és limitat. Diverses indústries demanden nous graus d'acer amb menor densitat per a disminuir el pes sense comprometre les propietats mecàniques. Els acers amb alt contingut en manganés es consideren materials molt prometedors per a aplicacions estructurals a causa de la seua excepcional combinació de resistència i ductilitat, amb una baixa densitat. No obstant això, malgrat les seues excepcionals propietats, els acers amb alt contingut en manganés s'enfronten a diverses limitacions o reptes durant les tècniques de processament convencionals. Afortunadament, la solidificació ràpida pot resoldre estos problemes. En este sentit, les tecnologies d'AM basades en làser proporcionen velocitats de refredament ràpides, així com flexibilitat en termes de disseny geomètric. Els nous reptes d'estes tecnologies implicaran la microsegregació i l'esquerdament en calent, o hot cracking en anglés, que es produïxen durant la solidificació. Esta tesi està dedicada a explotar el mètode CALPHAD per a realitzar càlculs termodinàmics amb la finalitat de dissenyar diversos acers amb alt contingut en manganés que puguen previndre eficaçment els problemes de solidificació ràpida en AM. Les composicions d'acer dissenyades es van produir en forma de pols per a AM mitjançant atomització amb gas. Es van analitzar les pólvores per a determinar la seua microestructura en relació amb la química i la velocitat de refredament. Ajustant adequadament els paràmetres d'impressió, estes pólvores d'acer amb alt contingut en manganés es van imprimir amb èxit en AM, donant lloc a densitats relatives superiors al 99.9%. Es va analitzar la microestructura d'estes mostres totalment denses i es va comparar amb les seues respectives pólvores, amb la finalitat d'identificar qualsevol diferència resultant de les variacions en la velocitat de refredament i els cicles tèrmics. Finalment, desprès de definir el millor conjunt de condicions d'impressió per a cada composició de pols, es van produir diverses mostres per a avaluar les propietats mecàniques. / [EN] Additive manufacturing (AM) is a process that builds three-dimensional solid objects by layering materials based on a computer-aided design model. AM is set to become the next industrial revolution, transforming the landscape of development and production. AM provides numerous benefits, including complex and flexible design possibilities, the elimination of intermediate processes like machining, production cost independence from batch size, reduced material waste, lightweight structures, customized machine repairs, and the ability to develop new materials, among other advantages. In additive manufacturing technologies that employ a laser beam as an energy source, the initial raw material (in the form of powder or wire) is melted by the laser heat source in a controlled manner, layer by layer, until a component with final or nearly final dimensions is created. These technologies involve subjecting the printed material to a unique thermal process, where the material is melted in a very specific area and then rapidly cooled at extremely high rates of up to 10^6 K/s. Hence, the microstructures that arise from the manufacturing processes in AM differ significantly from those achieved in traditional processes. Moreover, the materials predominantly employed in AM have not been explicitly designed for these technologies. The specific characteristics of AM processes can be utilized to achieve distinct microstructures and properties in steels that have been tailored to take advantage of the rapid cooling rates and thermal history of the process, among other factors. For the moment, the number of commercial steel grades available in the AM market is limited. Various industries are demanding new steel grades with lower density to decrease weight without compromising mechanical properties. High manganese steels are regarded as highly promising materials for structural applications due to their exceptional combination of strength and ductility, with low density. Nevertheless, despite the exceptional properties of high manganese steels, they encounter various limitations or challenges during conventional processing techniques. Fortunately, rapid solidification may solve these issues. In this sense, laser-based AM technologies provide rapid cooling rates, as well as flexibility in terms of geometric design. The new challenges of these technologies will involve micro-segregation and hot cracking occurring during solidification. This thesis is dedicated to exploiting the CALPHAD method to perform thermodynamic calculations in order to design various high manganese steels that can effectively prevent fast solidification issues in AM. The steel compositions designed were produced in the form of powder for AM using gas atomization. Powders were analyzed to determine their microstructure in relation to the chemistry and cooling rate. By adjusting properly, the printing parameters, these high manganese steel powders were successfully printed in AM, resulting in relative densities exceeding 99.9%. The microstructure of these fully dense samples was analyzed and compared to their respective powders, in order to identify any difference resulting from variations in cooling rate and thermal cycling. Lastly, after defining the best set of printing conditions for each powder composition, various samples were produced to evaluate the mechanical properties, to determine the correlation between the composition, microstructure and properties of these steels. In addition, lattice structures that are close to final part geometries were constructed to quantify the energy absorbed during compression by one of these high manganese steels. The results were then compared to those of 316L, revealing that the high manganese steel absorbs roughly twice as much the specific energy in compression. This finding demonstrates the potential of these novel AM steels for use in industrial applications. / Sánchez Poncela, M. (2024). Design of High Mn Fe-Mn-Al-C Low Density Steels for Additive Manufacturing [Tesis doctoral]. Universitat Politècnica de València. https://doi.org/10.4995/Thesis/10251/205174

<p>Combination of the Calphad method and theoretical calculations provides new possibilities for the study of materials science. This work is a part of the efforts within the CCT project (Centre of Computational Thermodynamics) to combine these methods to facilitate modeling and to extend the thermodynamic databases with critically assessed volume data. In this work, the theoretical calculations refer to first-principles and Debye-Grüneisen calculations. The first-principles (i.e. ab initio) electronic structure calculations, based on the Density- Functional Theory (DFT), are capable of predicting various physical properties at 0 K, such as formation energy, volume and bulk modulus. The ab initio simulation software, VASP, was used to calculate the binding curves (i.e. equation of state at 0 K) of metallic elements, cubic carbides and nitrides. From the binding curves, the equilibrium volumes at 0 K were calculated for several metastable structures as well as stable structures. The vibrational contribution to the free energy was calculated using the Debye-Grüneisen model combined with first-principles calculations. Two different approximations for the Grüneisen parameter, γ, were used in the Debye-Grüneisen model, i.e. Slater’s and Dugdale-MacDonald’s expressions. The thermal electronic contribution was evaluated from the calculated electronic density of states. The calculated thermal expansivities for metallic elements, cubic carbides and nitrides were compared with Calphad assessments. It was found that the experimental data are within the limits of the calculations using the two approximations for γ. By fitting experimental heat capacity and thermal expansivity around Debye temperatures, we obtained optimal Poisson’s ratio values and used them to evaluate Young’s and Shear moduli. In order to reach a reasonable agreement with the experiments, it is necessary to use the logarithmic averaged mass of the constitutional atoms. The agreements between the calculations and experiments are generally better for bulk modulus and Young’s modulus than that for shear modulus. A new model describing thermodynamic properties at high pressures was implemented in Thermo-Calc. The model is based on an empirical relation between volume and isothermal bulk modulus. Pure Fe and solid MgO were assessed using this model. Solution phases will be considered in a future work to check the model for compositional dependence.</p>

Combination of the Calphad method and theoretical calculations provides new possibilities for the study of materials science. This work is a part of the efforts within the CCT project (Centre of Computational Thermodynamics) to combine these methods to facilitate modeling and to extend the thermodynamic databases with critically assessed volume data. In this work, the theoretical calculations refer to first-principles and Debye-Grüneisen calculations. The first-principles (i.e. ab initio) electronic structure calculations, based on the Density- Functional Theory (DFT), are capable of predicting various physical properties at 0 K, such as formation energy, volume and bulk modulus. The ab initio simulation software, VASP, was used to calculate the binding curves (i.e. equation of state at 0 K) of metallic elements, cubic carbides and nitrides. From the binding curves, the equilibrium volumes at 0 K were calculated for several metastable structures as well as stable structures. The vibrational contribution to the free energy was calculated using the Debye-Grüneisen model combined with first-principles calculations. Two different approximations for the Grüneisen parameter, γ, were used in the Debye-Grüneisen model, i.e. Slater’s and Dugdale-MacDonald’s expressions. The thermal electronic contribution was evaluated from the calculated electronic density of states. The calculated thermal expansivities for metallic elements, cubic carbides and nitrides were compared with Calphad assessments. It was found that the experimental data are within the limits of the calculations using the two approximations for γ. By fitting experimental heat capacity and thermal expansivity around Debye temperatures, we obtained optimal Poisson’s ratio values and used them to evaluate Young’s and Shear moduli. In order to reach a reasonable agreement with the experiments, it is necessary to use the logarithmic averaged mass of the constitutional atoms. The agreements between the calculations and experiments are generally better for bulk modulus and Young’s modulus than that for shear modulus. A new model describing thermodynamic properties at high pressures was implemented in Thermo-Calc. The model is based on an empirical relation between volume and isothermal bulk modulus. Pure Fe and solid MgO were assessed using this model. Solution phases will be considered in a future work to check the model for compositional dependence.

Alumino-silicate systems are of great interest for materials scientists and geochemists. Thermodynamic knowledge of these systems is useful in steel and ceramic industries, and for understanding geochemical processes. A popular and efficient approach used to obtain a self-consistent thermodynamic dataset is called CALPHAD. It couples phase diagram information and thermochemical data with the assistance of computer models. The CALPHAD approach is applied in this thesis to the thermodynamic modelling and assessments of the CaO-Al2O3-SiO2, MgO-Al2O3-SiO2 and Y2O3-Al2O3-SiO2 systems and their subsystems. The compound energy formalism is used for all the solution phases including mullite, YAM, spinel and halite. In particular, the ionic two sub-lattice model is applied to the liquid solution phase. Based both on recent experimental investigations and theoretical studies, a new species, AlO2-1, is introduced to model liquid Al2O3. Thus, the liquid model corresponding for a ternary Al2O3-SiO2-M2Om system has the formula (Al+3,M+m)P (AlO2-1,O-2, SiO4-4,SiO20)Q, where M+m stands for Ca+2, Mg+2 or Y+3. This model overcomes the long-existing difficulty of suppressing the liquid miscibility gap in the ternary systems originating from the Al2O3-free side during the assessments. All the available and updated experimental information in these systems are critically evaluated and finally a self-consistent thermodynamic dataset is achieved. The database can be used along with software for Gibbs energy minimization to calculate any type of phase diagram and all thermodynamic properties. Various phase diagrams, isothermal and isoplethal sections, and thermochemical properties are presented and compared with the experimental data. Model calculated site fractions of species are also discussed. All optimization processes and calculations are performed using the Thermo-Calc software package. / QC 20100607

The recent emphasis on magnesium alloys can be appreciated by following the research push from several agencies, universities and editorial efforts. With a density equal to two-thirds of Al and one-thirds of steel, Mg provides the best opportunity for lightweighting of metallic components. However, one key bottleneck restricting its insertion into industrial applications is low strength values. In this respect, Mg-Y-Nd alloys have been promising due to their ability to form strengthening precipitates on the prismatic plane. However, if the strength is compared to Al alloys, these alloys are not attractive. The primary reason for low structural performance in Mg is related to low alloying and microstructural efficiency. In this dissertation, these terminologies are discussed in detail. A simple calculation showed that the microstructural efficiency in Mg-4Y-3Nd alloy is 30% of its maximum potential. Guided by the definitions of alloying and microstructural efficiency, the two prime objectives of this thesis were to: (i) to use thermomechanical processing routes to tailor the microstructure and achieve high strength in an Mg-4Y-3Nd alloy, and (ii) optimize the alloy chemistry of the Mg-rare earth alloy and design a novel rare—earth free Mg alloy by Calphad approach to achieve a strength of 500 MPa. Experimental, theoretical and computational approaches have been used to establish the process-structure-property relationships in an Mg-4Y-3Nd alloy. For example, increase in strength was observed after post aging of the friction stir processed/additive manufactured microstructure. This was attributed to the dissolution of Mg2Y particles which increased the alloying and microstructural efficiency. Further quantification by numerical modeling showed that the effective diffusivity during friction stir processing and friction stir welding is 60 times faster than in the absence of concurrent deformation leading to the dissolution of thermally stable particles. In addition, the investigation on the interaction between dislocations and strengthening precipitate revealed that, specific defects like the I1 fault aid in the accelerated precipitation of the strengthening precipitate in an Mg-4Y-3Nd alloy. Also, the effect of external field (ultrasonic waves) was studied in detail and showed accelerated age hardening response in Mg-4Y-3Nd alloy by a factor of 24. As the bottleneck of low strength is addressed, the answers to the following questions are discussed in this dissertation: What are the fundamental micro-mechanisms governing second phase evolution in an Mg-4Y-3Nd alloy? What is the mechanical response of different microstructural states obtained by hot rolling, friction stir processing and friction stir additive manufacturing? Is defect engineering critical to achieve high strength Mg alloys? Can application of an external field influence the age hardening response in an Mg-4Y-3Nd alloy? Can a combination of innovative processing for tailoring microstructures and computational alloy design lead to new and effective paths for application of magnesium alloys?