Experimental Analysis of an AZ31 Magnesium Alloy Structural FPV Drone Frame: Comparison with Aluminum and Carbon Fiber

This study investigates the thermal and vibration-attenuation performance of a novel 7-inch FPV drone frame manufactured from cast AZ31 magnesium alloy (MG), compared to 6061-T6 aluminum (AL) and carbon fiber (CF) composite structures under an extreme payload of 2 kg. Using quantitative spectral analysis of Blackbox flight logs, the research demonstrates that the MG frame provides superior system-level vibration damping, particularly under high-stress conditions. Under a 2 kg payload, the MG frame exhibited a 49% reduction in vibration power compared to the AL frame. Spectral data identified primary resonance peaks for the MG frame at 147 Hz (0 kg) and 204 Hz (2 kg), whereas the AL frame showed significantly higher frequency peaks at 179.5 Hz (0 kg) and 239.4 Hz (2 kg). Comparative modal hammer tests further validated these findings, with the magnesium design exhibiting lower impulse energy (0.22 mW/Hz) and faster decay than aluminum (0.24 mW/Hz). Thermal imaging analysis showed better motor cooling for the metallic frames; average motor temperatures on the magnesium frame (51.8 °C) and AL frame (50.3 °C) were significantly lower than on the CF structure (77.5 °C). The findings establish that AZ31 magnesium alloy offers an excellent synergy of lightweight stiffness and damping capacity, making it a viable alternative for heavy-duty FPV platforms requiring high signal integrity.