The work presents an analysis of selected magnesium alloys as structural materials to be used in production of aircraft parts as well as their technological parameters in some manufacturing processes. Upsetting test, backward extrusion and Kobo extrusion of complex cross-sectional profiles and forging process were realized using magnesium alloys AZ31, AZ61, AZ80, WE 43 and Mg alloy with Li for production of thin - walled aircraft profiles and forged aviation parts. The range of temperatures and extrusion rate for the manufacturing these profiles were determined. Tests also covered the analysis of microstructure of Mg alloys in the initial state as well as after the extrusion process. It has been proved that the proper choice of parameters in the case of a specific profile extruded from magnesium alloys allows the manufacturing of products of complex cross-sections and the quality required in aerospace industry. This has been demonstrated on the examples of complex cross-sectional profiles using elements of varied wall thickness and examples of forged aviation parts: aircraft wheel hub and helicopter lever for control system.

The effect of 2 mass% rare earth elements (RE) as in mischmetal state on the structure, thermal behaviour and mechanical properties of Mg–xLi–4Al (x = 4, 8 and 12 by mass percentage). The thermo-derivative analysis was implemented using the UMSA platform (Universal Metallurgical Simulator and Analyzer) with cooling rate approx. ≈ 0.6 °C s⁻¹ that correspond to natural cooling. Microstructural evaluations were identified by X-ray diffraction, scanning electron microscopy, light microscope and energy-dispersive X-ray spectroscopy. Obtained results from the thermal derivative analysis allowed determining the solidification pathways for Mg–Li–Al–RE alloy. The addition of grain refinement causes changes in crystallisation process. The addition of RE elements affected an enhancement in mechanical properties, which was associated with the development of intermetallic compounds; the maximum increases in hardness at level 240% was observed for single α-phase alloy and at level 19% for α + β alloy.

The problem of preparing a ternary powder mixture, which was meant to fabricate sintered heterophase composite, and consisted of micro- and two nanosized powders, was analyzed. The microsized powder was a pure magnesium, and as nanocomponents, a silicon powder (nSi) and carbon nanotubes (CNTs) with 2% and 1% volume fractions, respectively, were applied. The powder mixtures were prepared using ultrasonic and mechanical mixing in technological fluid, and four mixing variants were applied. The morphology of the powder mixtures was characterized with scanning electron microscopy (SEM), and then, composite sinters were fabricated in a vacuum with hot temperature pressing at 580 °C under 15 MPa pressure, using a Degussa press. The reaction between the nSi and the Mg matrix, which caused the creation of the Mg₂Si phase in the fabricated Mg-Mg₂Si-CNT composite, was confirmed with X-ray diffraction (XRD). The porosity and hardness of the composite sinters were examined, and optical microscopy (OM) and quantitative image analyses were carried out to characterize the microstructure of the composites. In the manufacturing process of the Mg-nSi-CNT mixtures, the best results were the following: first separate de-agglomeration of nanocomponents, then their common mixing, and finally, the deposition of nanocomponents at the surface of the microsized magnesium powder. The applied procedure ensured the uniform layer formation of de-agglomerated nanocomponents on the Mg powder, without re-agglomerated nSi and CNTs. Moreover, this type of powder mixture morphology allows to obtain sinters with lower porosity and higher hardness, which is accompanied by precipitation of a finer Mg₂Si phase. In the Mg-Mg₂Si-CNT composite, the carbon phase was present, and it was located in the magnesium matrix and in silicide.