The authors examined the properties of Mg
96Zn
2Y
2 alloy bars made through continuous consolidation of chip using a newly developed single screw extrusion machine designed for magnesium alloy chip. Surface conditions as well as microstructure of the consolidated Mg
96Zn
2Y
2 alloy varied depending on the die conditions. With a die inner diameter of 49 mm and die temperature of 723 K, severe plastic deformation in the die produced a fine-grain microstructure in the consolidated Mg
96Zn
2Y
2 alloy bar. The compounds such as Mg
12YZn and Mg
3Y
2Zn
3 in the bar were also dispersed finely. Owing to its randomized crystal orientation, a secondary extruded bar made from the consolidated Mg
96Zn
2Y
2 alloy bar showed a higher ductility than that of ingot-extruded bar. The fine-grain consolidated Mg
96Zn
2Y
2 alloy bar exhibited an elongation of 308% at 723 K. Furthermore, the deformation characteristics were examined with the consolidated Mg
96Zn
2Y
2 alloy bar for the purpose of determining its suitability as hot-processing material billets. The fine-grain consolidated Mg
96Zn
2Y
2 alloy bar was compressed without cracking up to 623 K while Mg
96Zn
2Y
2 ingot cracked. It was found that smaller grain diameter made the
m-value higher.
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