Magnesium molding

Magnesium alloys are available in a variety of metal forms, including cast ingots, slabs, and billets sand, permanent-mold, die, and investment castings forgings extmded bars, rods, tubes, stmctural and special hoUow and soHd shapes and roUed sheet and plate. Magnesium alloys are used widely in a great variety of appHcations. 

The cells are fed semicontinuously and produce both magnesium and chlorine (see Alkali and chlorine products). The magnesium collects in a chamber at the front of the cell, and is periodically pumped into a cmcible car. The cmcible is conveyed to the cast house, where the molten metal is transferred to holding furnaces from which it is cast into ingots, or sent to alloying pots and then cast. The ingot molds are on continuous conveyors. 

Heat Treating Sand and Permanent Mold Magnesium Castings, bull. no. 141—552, The Dow Chemical Co., Midland, Mich., 1987. 

Piebaked anodes aie produced by molding petroleum coke and coal tar pitch binder into blocks typically 70 cm x 125 cm x 50 cm, and baking to 1000—1200°C. Petroleum coke is used because of its low impurity (ash) content. The more noble impurities, such as iron and siUcon, deposit in the aluminum whereas less noble ones such as calcium and magnesium, accumulate as fluorides in the bath. Coal-based coke could be used, but extensive and expensive prepurification would be required. Steel stubs seated in the anode using cast iron support the anodes (via anode rods) in the electrolyte and conduct electric current into the anodes (Fig. 3). Electrical resistivity of prebaked anodes ranges from 5-6 Hm anode current density ranges from 0.65 to 1.3 A/crn. ... 

The metal parts of the injection molder, ie, the liner, torpedo, and nozzle, that contact the hot molten resin must be of the noncatalytic type to prevent accelerated decomposition of the polymer. In addition, they must be resistant to corrosion by HCl. Iron, copper, and zinc are catalytic to the decomposition and caimot be used, even as components of alloys. Magnesium is noncatalytic but is subject to corrosive attack, as is chromium when used as plating. Nickel alloys such as Duranickel, HasteUoy B, and HasteUoy C are recommended as constmction materials for injection-molding metal parts. These and pure nickel are noncatalytic and corrosion-resistant however, pure nickel is rather soft and is not recommended. 

Magnesium carbonate is extracted from dolomite rock, and after mixing with fiber reinforcement is slurry cast into appropriate molds. After drying, the products are machined to size. 

The third composition in Table IV seems to be related to the aromatic sulfonate/polycarbonate technology just discussed with some modifications being necessary in order to compensate for the aliphatic nature of the polypropylene (17. 181 substrate. In this case the aromatic sulfonate is replaced with a metal salt (preferably magnesium stearate). A silicone oil and or gum has been added to enhance the intumescent character and a small amount of inert filler and decabromodiphenyl oxide is included probably to improve the molding characteristics of the total composition. Fire retardant compositions with a good surface char can be obtained at total loadings only about half that required for the halogen/antimony oxide composition. 

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