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.

Influence of the methodology of mathematical processing of experimental data on the calculated value of the activation energy in hot forming was evaluated for three very different alloys: iron aluminide, low-alloyed steel and magnesium alloy. Application of the mean strain rates is appropriate but calculations with use of nominal strain rates of the plastometric tests do not give significantly different results. Calculations based on the processing of the simplified power dependence between strain rate and peak stress can give the results differing very substantially from those that were gained by the solution of the complex hyperbolic relationship. This has negative impacts, particularly at prediction of the maximum flow stress in the broad range of forming conditions, represented by the Zener-Hollomon parameter.

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