Magnesium ferrosilicon alloys

An alternative commercial form of a metallic mixed lanthanide-containing material is rare-earth siUcide [68476-89-1/, produced in a submerged electric-arc furnace by the direct reduction of ore concentrate, bastnasite, iron ore, and quart2. The resulting alloy is approximately 1/3 mischmetal, 1/3 sihcon, and 1/3 iron. In addition there are some ferro-alloys, such as magnesium—ferrosilicons, derived from cerium concentrate, that contain a few percent of cerium. The consumption of metallic cerium is overwhelmingly in the mixed lanthanide form in ferrous metallurgy. 

The various rare earths are used in the foundry industry as rare earth silicides, in which the rare earth content is about 30%. Other alloys are used in which the level of rare earths is about 10% (10% cerium, 2% other rare earths) with silicon and iron comprising the bulk of the remaining elements. In the magnesium-ferrosilicon alloys, the rare earths are present in amounts from about 0.1% to 1.0%. These alloys are used differently by the various consumers. However, the effects of the rare earth elements, introduced by whatever means, are the same. 

Magnesium ferrosilicon alloys react vigorously when added to molten iron. As the magnesium vaporizes and cools, it reacts with residual surface tension modifiers such as sulfur and oxygen and greatly increases the surface tension of the molten iron. The dissolved graphite in the molten iron nucleates and grows into a spheroidal shape because of the increased surface tension of the molten iron. 

Metallic magnesium is produced by either chemical or electrolytic reduction of its compounds. In chemical reduction, first magnesium oxide is obtained from the decomposition of dolomite. Then ferrosilicon, an alloy of iron and silicon, is used to reduce the MgO at about 1200°C. At this temperature, the magnesium produced is immediately vaporized and carried away. The electrolytic method uses seawater as its principal raw material magnesium hydroxide is precipitated by adding slaked lime (Ca(OH)2, see Section 14.10), the precipitate is filtered off and treated with hydrochloric acid to produce magnesium chloride, and the dried molten salt is electrolyzed. 

It should be recalled that the final step in the nodular iron treatment process is termed "post inoculation." The purpose of this procedure is to aid in the elimination of iron carbides and promote enhanced nucleation and proper growth of graphite spheroids. This is accomplished by the introduction of the element silicon (usually a ferrosilicon alloy) along with calcium and maybe some magnesium or rare earth. It has been demonstrated that the benefits of rare earth additions are not affected as a function of the time in the process that they are added (23). For example, the elimination of iron carbides by use of the rare earths is possible if the rare earths are introduced along with the primary nodulizer or with the post inocu-lant. In passing, it should be remarked that both the primary nodulizers and ferrosilicon inoculants contain about 1% calcium. 

The second method involves reacting magnesium oxide with ferrosilicon. Ferrosilicon is an alloy of iron and silicon. When magnesium oxide and ferrosilicon react, free magnesium metal is formed. 

Magnesium chloride is readily available in vast quantities from seawater, and this method is still used today. A second modern method is the ferrosilicon process, in which fused carbonate mixtures react with an alloy of iron and silicon, as shown... 

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