An extruded magnesium AZ31 magnesium alloy was processed by rotary swaging (RSW) and then deformed by tension and compression at room temperature. The work-hardening behaviour of 1–5 times swaged samples was analysed using Kocks-Mecking plots. Accumulation of dislocations on dislocation obstacles and twin boundaries is the deciding factor for the strain hardening. Profuse twinning in compression seems to be the reason for the higher hardening observed during compression. The main softening mechanism is apparently the cross-slip between the pyramidal planes of the second and first order. A massive twinning observed at the deformation beginning influences the Hall-Petch parameters.

The microstructure and mechanical properties of AZ31 alloy rods are investigated after rotary swaging in five successive steps. The microstructure is analyzed using light microscopy and electron backscattered diffraction. Swaged samples exhibit refined microstructure. Tensile and compression tests are conducted at room temperature. The yield stress and the ultimate stress are determined. Acoustic emission is measured in situ during straining. Deformation mechanisms are closely linked to twinning and dislocation slip in non‐basal planes.

The magnesium AZ31 alloy was swaged with rotary pressure with the aim of redefining the microstructure and improving mechanical and fatigue properties. The rotary swaging process and subsequent ageing improved the yield stress in tension and compression. In the present study, the investigation was focused on fatigue behaviour. The samples were cycled in a symmetric regime with a frequency of 35 Hz. A dependence of the stress amplitude on the number of cycles up to the fracture was estimated. The microstructure of the samples and fracture surfaces was analysed with a scanning electron microscope. The fatigue process was influenced by the pronounced texture formed in the swaging process. The fatigue properties of the swaged samples improved substantially—the endurance limit based on 107 cycles was approximately 120 MPa—compared to those of the cast alloy. The analysis of the fracture surfaces showed a transcrystalline fatigue fracture.