The paper presents the theoretical and technological aspects of forming magnesium alloy parts for aircraft and automotive applications. The main applications of magnesium alloys in the aircraft and automotive industries are discussed. In addition, the forging technology for magnesium alloys is generally described, with a particular emphasis on wrought alloys. A brief outline of the state of the art in the forging of magnesium alloys is given based on a survey of the specialist literature and the results of previous research by the authors.

The results of research on friction conditions of alloys: magnesium Mg4AlZn, titanium Ti6Al4V and aluminum 6101A are presented in this paper. The aim of these research was determining values of friction factors and coefficients, which characterize constant friction model and Coulomb's model within the range of hot metal forming temperatures at various lubrication conditions. In the research works the ring tests were applied. For the alloy Mg4AlZn the samples were heated to the temperatures: 250 • C, 350 • C and 450 • C, for aluminum alloy 6101A to the temperatures: 350 • C, 400 • C, 450 • C and for alloy Ti6Al4V to the temperatures: 850 • C, 900 • C, 950 • C. Tests were made in conditions of friction without lubrication and with the application of lubricants: tallow with graphite, Aquagraphite CP, Lubrodal-F318 and on the basis of molybdenum disulfide.Friction factors and coefficients values were determined on the basis of comparison of experimental research results wih results of the conducted tests simulations. The value of factor and coefficient which guaranteed the best convergance of theoretical and experimental dimensions of upset samples was assumed as optimal. On the basis of the obtained results the influence of temperature on friction conditions and effectiveness of the used lubricants were determined in relation to analyzed alloys.W opracowaniu przedstawiono wyniki badań warunków tarcia stopów: magnezu Mg4AlZn, tytanu Ti6Al4V oraz aluminium 6101A. Celem badań było wyznaczenie wartości czynników i współczynników tarcia charakteryzujących odpowiednio model tarcia stałego oraz model Coulomba w zakresie temperatur obróbki plastycznej na gorąco przy różnych warunkach smarowania. W badaniach zastosowano metodę spęczania próbki pierścieniowej. Dla stopu Mg4AlZn próbki nagrzewano do temperatur: 250 • C, 350 • C oraz 450 • C, dla stopu aluminium 6101A do temperatur: 350 • C, 400 • C, 450 • C oraz dla stopu Ti6Al4V do temperatur: 850 • C, 900 • C, 950 • C. Testy wykonano w warunkach tarcia suchego oraz z zastosowaniem smarów: łoju z grafitem, Akwagrafitu CP, Lubrodalu-F318 oraz na bazie dwusiarczku molibdenu.Wartości czynników i współczynników tarcia wyznaczono na podstawie porównania wyników doświadczalnych z rezultatami symulacji przeprowadzonych testów. Za optymalną przyjmowano taką wartość współczynnika lub czynnika tarcia, która zapewniła najlepszą zbieżność pomiędzy teoretycznymi i doświadczalnymi wymiarami spęczonych próbek. Na podstawie uzyskanych rezultatów określono wpływ temperatury na warunki tarcia oraz skuteczność użytych smarów w odniesieniu do badanych stopów.

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Purpose -The purpose of this paper is to determine time-to-ignition of magnesium alloy chips and the ignition-preceding stages as well as to examine chip morphology. The tests were conducted according to the following pattern: directly after a milling operation, after ignition using a special test stand located outside the machine tool and after intensive oxidation which prevented ignition. Design/methodology/approach -Milling is a machining process widely used in the manufacturing of various parts that are applied, e.g. in the aircraft industry. Milling is used for both roughing and finishing machining. In the dry machining of magnesium alloys, spontaneous ignition can occur; therefore, the analysis of chip temperature in the cutting area is of great significance. Additionally, time-to-ignition and chip morphology are crucial when considering the safety of magnesium alloy machining processes. Findings -The experimental results demonstrate the effect of parameters of the milling process on time-to-ignition of chips made of magnesium alloys AZ31 and AZ91HP. The experiments also involved examining the morphology of a selection of chips produced at the maximum cutting velocity vc and feed per tooth fz. In addition, we analysed the morphology of both ignition products and chips subjected to high temperature where ignition did not occur. Practical Implications -Based on the time-to-ignition and chip morphology results, it is possible to indicate both safety levels in machining and the efficient range of parameters in the milling of aircraft parts made of magnesium alloys. Originality/value -The paper presents a new approach to assessing safety in milling operations. The results of the tests of chip flammability (time-to-ignition) which were run at a special test stand placed outside the machine tool enabled determination of both safety and efficiency range of the milling process.