Metals Advances ›› 2026, Vol. 46: 1-16.DOI: 10.1016/j.metadv.2026.02.034
• Review Article • Next Articles
Jing Tana,b, Baodong Shia,b,c,d,*(
), Xianhua Chena,b,c,*(
)
Received:2025-12-18
Revised:2026-01-24
Accepted:2026-01-27
Online:2026-08-10
Published:2026-02-18
Contact:
*College of Materials Science and Engineering, Chongqing University, Chongqing 400045, China. E-mail addresses: baodong.shi@ysu.edu.cn (B. Shi),xhchen@cqu.edu.cn (X. Chen).
Jing Tan, Baodong Shi, Xianhua Chen. Exploring plastic deformation behavior and underlying mechanisms of magnesium alloy: Progress in single length-scale approaches and frontiers in cross-scale linkages[J]. Metals Advances, 2026, 46: 1-16.
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| Scale/Method | Core function | Cross-scale role | Inherent limitations | Ref. |
|---|---|---|---|---|
| Atomic scale (DFT) | Calculate fundamental energy descriptors (SFE, GSFE). | Provide input parameters (SFE, interface energies) for higher-scale models. | High computational cost; limited to ∼100-1000 atoms; cannot simulate dynamics. | [ |
| Atomic scale (MD) | Simulate the dynamic evolution of defects (dislocations, twins). | Provide kinetic data (dislocation velocities) and insights into defect-core structures. | Restricted to nanoscale and picosecond-nanosecond timescales; accuracy depends on the interatomic potential. | [ |
| Mesoscopic scale (PF) | Model microstructure evolution (grain growth, DRX, twinning). | Predict microstructural states that define initial conditions for CPFEM/FEM. | Computationally intensive for large volumes; often relies on phenomenological parameters. | [ |
| Mesoscopic scale (CPFEM) | Link crystal-scale mechanisms to polycrystalline response. | Calibrate macroscopic constitutive laws; provide sub-grid scale physics for FEM. | Prohibitively expensive for full-component simulations; requires simplification of complex defect interactions. | [ |
| Macroscopic scale (FEM/CM) | Simulate component-level forming processes and optimize parameters. | Provide boundary conditions for lower-scale models in a top-down manner. | Often lacks physical mechanisms; parameters require extensive calibration, limiting predictability. | [ |
Table 1. Cross-scale roles and inherent limitations of single-scale simulation methods.
| Scale/Method | Core function | Cross-scale role | Inherent limitations | Ref. |
|---|---|---|---|---|
| Atomic scale (DFT) | Calculate fundamental energy descriptors (SFE, GSFE). | Provide input parameters (SFE, interface energies) for higher-scale models. | High computational cost; limited to ∼100-1000 atoms; cannot simulate dynamics. | [ |
| Atomic scale (MD) | Simulate the dynamic evolution of defects (dislocations, twins). | Provide kinetic data (dislocation velocities) and insights into defect-core structures. | Restricted to nanoscale and picosecond-nanosecond timescales; accuracy depends on the interatomic potential. | [ |
| Mesoscopic scale (PF) | Model microstructure evolution (grain growth, DRX, twinning). | Predict microstructural states that define initial conditions for CPFEM/FEM. | Computationally intensive for large volumes; often relies on phenomenological parameters. | [ |
| Mesoscopic scale (CPFEM) | Link crystal-scale mechanisms to polycrystalline response. | Calibrate macroscopic constitutive laws; provide sub-grid scale physics for FEM. | Prohibitively expensive for full-component simulations; requires simplification of complex defect interactions. | [ |
| Macroscopic scale (FEM/CM) | Simulate component-level forming processes and optimize parameters. | Provide boundary conditions for lower-scale models in a top-down manner. | Often lacks physical mechanisms; parameters require extensive calibration, limiting predictability. | [ |
Fig. 2. (a) The generalized fault energy and surface energy of the Mg, Mg-Zn and Mg-Zn-R models were calculated in the DFT, and the formability and surface stability of magnesium alloys were evaluated; (b) Details of the compression twin and slip trace by MD at 300 K [52], [76].
Fig. 3. (a) Two-dimensional slices of the pure Mg NC model, the Mg-0.3Y NC model containing randomly distributed Y atoms and the Y-segregated Mg-0.3Y NC model; (b) Molecular dynamics analysis of plastic deformation of Mg-14Li-7Al alloy; (c) The atomic climb processes of <a> and <c+a> dislocations in Mg lattice and the corresponding energy evolution during <a> and <c+a> dislocation climb [81], [84], [86].
Fig. 4. (a) The corrected BKS model describes the influence of precipitated phase size on strengthening and effectively predicts the variation trend of CRSS with precipitated phase size and distribution; (b) Two-dimensional phase field model (PF-DDRX-SP) [21], [98].
| Scale/method | Simulation strategy | Solve core problems | Ref. |
|---|---|---|---|
| Atomic scale | Molecular dynamics (MD) | Revealing the atomic mechanism of twinning nucleation and growth. | [ |
| Analyze the activation and cross-slip penetration mechanisms of non-fundamental plane dislocation slip. | [ | ||
| Predict the deformation coordination and failure behavior dominated by the prediction interface (grain boundary/phase boundary). | [ | ||
| Density functional theory (DFT) | Predict the electronic scale influence of alloying elements on the plastic deformation mechanism. | [ | |
| Predict the phase transition behavior and the second phase strengthening mechanism. | [ | ||
| Mesoscopic scale | Crystal plasticity finite element method (CPFEM) | Study dynamic recrystallization. | [ |
| Study the mechanism of precipitation enhancement. | [ | ||
| Study the plastic deformation of magnesium single crystals. | [ | ||
| Phase field method (PFM) | Predict plastic anisotropy and texture evolution. | [ | |
| Quantify the influence of dynamic twinning-detwinning on cyclic deformation. | [ | ||
| Optimize the forming process parameters and suppress defects. | [ | ||
| Macroscopic scale | Finite element method (FEM) | Predict forming defects and optimize mold design. | [ |
| The coupled temperature field and friction model guide the temperature forming process. | [ | ||
| Constitutive model (CM) | Predict deformation and fracture failure behaviors. | [ | |
| Evaluation of superplastic forming. | [ | ||
| Predict the plastic deformation of magnesium alloys with random texture. | [ | ||
| Multiscale coupling strategies | DFT+MD+PFM | Grain boundaries control the precipitated phase. | [ |
| FEM+viscoplastic self-consistent model (VPSC) | Predict stress-strain behavior and texture evolution. | [ | |
| Machine learning (ML) | Rapid process optimization/defect control. | [ | |
| Microstructure - performance correlation | [ | ||
| Alloy design/interface mechanism. | [ |
Table 2. Roles of simulation methods in magnesium alloy plastic forming.
| Scale/method | Simulation strategy | Solve core problems | Ref. |
|---|---|---|---|
| Atomic scale | Molecular dynamics (MD) | Revealing the atomic mechanism of twinning nucleation and growth. | [ |
| Analyze the activation and cross-slip penetration mechanisms of non-fundamental plane dislocation slip. | [ | ||
| Predict the deformation coordination and failure behavior dominated by the prediction interface (grain boundary/phase boundary). | [ | ||
| Density functional theory (DFT) | Predict the electronic scale influence of alloying elements on the plastic deformation mechanism. | [ | |
| Predict the phase transition behavior and the second phase strengthening mechanism. | [ | ||
| Mesoscopic scale | Crystal plasticity finite element method (CPFEM) | Study dynamic recrystallization. | [ |
| Study the mechanism of precipitation enhancement. | [ | ||
| Study the plastic deformation of magnesium single crystals. | [ | ||
| Phase field method (PFM) | Predict plastic anisotropy and texture evolution. | [ | |
| Quantify the influence of dynamic twinning-detwinning on cyclic deformation. | [ | ||
| Optimize the forming process parameters and suppress defects. | [ | ||
| Macroscopic scale | Finite element method (FEM) | Predict forming defects and optimize mold design. | [ |
| The coupled temperature field and friction model guide the temperature forming process. | [ | ||
| Constitutive model (CM) | Predict deformation and fracture failure behaviors. | [ | |
| Evaluation of superplastic forming. | [ | ||
| Predict the plastic deformation of magnesium alloys with random texture. | [ | ||
| Multiscale coupling strategies | DFT+MD+PFM | Grain boundaries control the precipitated phase. | [ |
| FEM+viscoplastic self-consistent model (VPSC) | Predict stress-strain behavior and texture evolution. | [ | |
| Machine learning (ML) | Rapid process optimization/defect control. | [ | |
| Microstructure - performance correlation | [ | ||
| Alloy design/interface mechanism. | [ |
| Scale/Method | Core defect | Specific manifestations | Ref. |
|---|---|---|---|
| Atomic scale (MD) | Limitations in temporal/spatial scales | MD simulations can typically only be carried out in the nanoscale and nanosecond range, with dynamic processes (such as DRX) distortion. | [ |
| Atomic scale (DFT) | High computational cost and limited applicability | It requires high-performance computers and a large amount of memory; It is impossible to directly and effectively simulate the atomic movement during processes such as deformation and fracture. | [ |
| Mesoscopic scale (CPFEM) | Cost calculation and mechanism simplification | Simulating tens of thousands of grains requires supercomputing resources, while dislocation-twin interactions are often neglected. | [ |
| Mesoscopic scale (PFM) | Computational efficiency and scale limitations | There are many equations to solve, and the computational efficiency is low. When simulating the evolution of tissues in a large-scale area, it will consume a lot of time. | [ |
| Macroscopic scale (FEM) | The contradiction between computational efficiency and accuracy | The calculation is time-consuming, and the accuracy of the calculation results depends on the density and quality of the grid. | [ |
| Macroscopic constitutive model (MC) | The twin mechanism is overly simplified | Ignoring the synergistic effects of processes such as dislocation slip, grain boundary migration and dynamic recrystallization leads to deviations in the prediction of complex stress-strain behavior. | [ |
Table 3. Defect comparison in single-scale simulation.
| Scale/Method | Core defect | Specific manifestations | Ref. |
|---|---|---|---|
| Atomic scale (MD) | Limitations in temporal/spatial scales | MD simulations can typically only be carried out in the nanoscale and nanosecond range, with dynamic processes (such as DRX) distortion. | [ |
| Atomic scale (DFT) | High computational cost and limited applicability | It requires high-performance computers and a large amount of memory; It is impossible to directly and effectively simulate the atomic movement during processes such as deformation and fracture. | [ |
| Mesoscopic scale (CPFEM) | Cost calculation and mechanism simplification | Simulating tens of thousands of grains requires supercomputing resources, while dislocation-twin interactions are often neglected. | [ |
| Mesoscopic scale (PFM) | Computational efficiency and scale limitations | There are many equations to solve, and the computational efficiency is low. When simulating the evolution of tissues in a large-scale area, it will consume a lot of time. | [ |
| Macroscopic scale (FEM) | The contradiction between computational efficiency and accuracy | The calculation is time-consuming, and the accuracy of the calculation results depends on the density and quality of the grid. | [ |
| Macroscopic constitutive model (MC) | The twin mechanism is overly simplified | Ignoring the synergistic effects of processes such as dislocation slip, grain boundary migration and dynamic recrystallization leads to deviations in the prediction of complex stress-strain behavior. | [ |
Fig. 6. (a) An integrated computing strategy based on the weakly coupled FEM-VPSC model; (b) Diffusion activation energy curve of Al in matrix and at grain boundary; (c) Dislocation configuration (Circles 1 and 2 show the 1/6<112> dislocation network and 1/3<100> dislocation network, respectively) [130], [136].
Fig. 7. A machine learning strategy integrating target performance determination, backward and forward modeling, and feature importance analysis [139].
Fig. 8. (a) Interpretable machine learning design strategy for high-performance low-alloyed Mg alloys, and excavating high-performance low-alloyed Mg alloys; (b) Schematic diagram of the active learning design strategy workflow [140], [142].
Fig. 9. By integrating DFT computational data points and machine learning methods, a widely applicable DLP was created to study the dislocation behavior of Mg [41].
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