• Micro X-ray computed tomography enables non-destructive 3D visualization of intermetallic phases in magnesium alloys, overcoming limitations of 2D metallography.
• The study characterizes Al-Mn and eutectic intermetallics in both industrial Mg-Al-Zn and novel Mg-Ni-Gd-Y alloys, revealing their nucleation, growth, and spatial distribution.
• 3D analysis provides insights into the morphology and interconnectivity of intermetallic networks, which are critical for optimizing solidification processes and alloy properties.
• Findings have significant implications for improving melt purity, corrosion resistance, and microstructural uniformity in magnesium alloy production and recycling.