MAGNESIUM FOUNDRY

INTRODUCTION
Magnesium alloy castings can be produced by nearly all of the conventional casting methods,
namely, sand, permanent, and semi-permanent mold and shell, investment, and die-casting. The
choice of a casting method for a particular part depends upon factors such as the configuration
of the proposed design, the application, the properties required, the total number of castings
required, and the properties of the alloy. Magnesium castings of all types have found use in
many commercial applications, especially where their lightness and rigidity are a major
advantage, such as for chain saw bodies, computer components, camera bodies, and certain
portable tools and equipment. Magnesium alloy sand castings are used extensively in aerospace
components. Pure magnesium melts at a temperature of about 650C.
MAGNESIUM PROPERTIES
Magnesium is placed in the 2A series of the periodic table with an atomic number of 12. It has
a hexagonal close packed (HCP) crystal structure and is bright silver in color. The physical and
thermal properties of the pure magnesium are presented in the Table 1. The mechanical
properties of pure magnesium depend on the processing route as shown in Table 2.

MELTING OF MAGNESIUM
Magnesium may be melted in gas-fired or electric furnaces, including induction furnaces. Steel
crucibles are equipped with an additional outer layer of heat-resistant high-alloy steel for added
lifetime. These furnaces have two important design features:

Firebrick Material--- the refractory material on the walls and bottom of the furnace are
made from clay firebrick material (high alumina, low silica) for less reactivity (i.e., if
there is liquid magnesium leakage into the furnace chamber) and
Drag-out hole--- for access to allow cleaning of the furnace bottom for liquid
magnesium drainage in emergency (Fig 1). Frequent periodic cleaning of the furnace
bottom is performed to remove any oxidized metal scale that may have fallen off the
sides of the crucible. This scale may combine with air and liquid magnesium (in case of
crucible leak) to form thermite, which is a very high temperature reaction and
exothermic.

Before melting magnesium alloys, ensure that the following steps are followed:

The proper fire extinguishing materials are on hand and fully functional (i.e., such as
Class D fire extinguishers, M130 fused magnesium salt flux or dry sand)
Check that the protective cover gas is operating and in ample supply, if a complete
fluxless remelting operation is desired.

TRIMMING AND DRESSING

Castings must not be removed from the mold too quickly since they will distort when
hot; the temperature should preferably be less than 300C.
After cooling the castings should then be sent for fettling. Runners and risers are most
readily removed with a band saw.
Rectification of defective castings may be done by scraping or filing the defects and
then the cavity is surrounded by floor moulding sand so that the molten casting alloy
can be poured to weld up satisfactorily the casting surface and the new metal.

CASTING OPERATIONS

Pouring should be carried out smoothly.

Hand ladle used for pouring the die casting should be preheated to red heat and when
not in immediate use must be kept hot.
A sequence should be established for opening the die so that adequate time is allowed
for solidification and cooling of the casting and the removal of cores and pieces in a
manner least likely to give rise to distortion while the metal is still somewhat plastic.
Further to the question of casting withdrawal, it should be noted that maintenance of a
vertical position for the casting is often essential, especially if massive sections are
situated at the base of the casting.
After taking out from the die, the casting should be placed in a warm place rather than
to lie them on the cold floor.