Abstract. The effect of roller burnishing on Vickers' hardness and positron lifetimes in the AZ91HP magnesium alloy was studied. The microhardness increases with an increase in the burnishing force and with a decrease in the feed. The comparison of various methods of analysis of positron annihilation lifetime (PAL) spectra allowed identifi cation of two components, which are related to solute-vacancy complexes and vacancy clusters, respectively. It was found that the increase in microhardness was related to the increase in the concentration of vacancy clusters.