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FAQs

WHAT IS MAGNESIUM?

Magnesium – atomic symbol Mg and atomic number 12 – is one of the most abundant elements in the earth’s crust. It occurs in nature principally as the minerals magnesite [MgCO3] and dolomite [(MgCaCO3] and in seawater where it is the third most plentiful component.

In its metallic form, magnesium metal has a number of significant properties that are invaluable in our advanced, technology driven environment. It is lightweight, less than two thirds the weight of aluminium, with a high strength-to-weight ratio. It also has high damping and rigidity properties and as such is finding increasing uses as a structural component in a number of industries, especially the automobile, aerospace and consumer product industries.

Magnesium metal can be machined faster and requires less energy than any of the commonly used structural metals such as steel and aluminium. This results in significant improvements in tool life and hence savings.

Magnesium alloys are relatively light – about 33% lighter than aluminium alloys and about 75% lighter than cast iron.  In the automotive sector, magnesium alloys (generally magnesium alloyed with aluminium and either zinc or manganese) are used to make die cast components such as steering wheels, suspension components, seat frames and brake parts.

WHAT ARE THE MAJOR APPLICATIONS OF MAGNESIUM?

Magnesium has a wide number of applications, both as the metal as well as a range of compounds, especially based on the oxide, MgO. Magnesium oxide is a major component of a wide range of ceramic and refractory materials used in domestic and industrial applications, and an important ingredient in various consumer products for the agricultural, horticultural and pharmaceutical sectors. Magnesium is an essential element for all living organisms, both animal and plant.

The traditional uses of magnesium metal fall into the following major categories:

  • as an additive to a wide range of aluminium alloys in pure magnesium form,
  • as an alloy of magnesium for die-casting, granules or wrought products (extrusion sheet plate),
  • as a chemical reductant for the production of other high-value metals, especially titanium, and as a catalyst or reagent in the industrial chemicals industry, and/or
  • as a means of purifying crude iron and steel products.

In some applications magnesium metal is used as such, but most applications involve the use of an alloy of magnesium. zinc, strontium, manganese, aluminium, beryllium and rare earth metals are the common alloying metals.

In the past the quality of the magnesium metal and/or alloy used in many of the above applications was not critical. However, most of the modern industrial applications of magnesium require a much higher grade of magnesium metal and/or alloy in order to impart the required physical and chemical properties, such as structural strength, corrosion and resistance.

These higher quality magnesium alloy products are available in a variety of forms including castings (die, sand, permanent mould and investment), extrusions, forgings and rolled products. Magnesium metal and its alloys can be joined by traditional welding and riveting techniques. As such, these products are finding increasing applications where the combined strength and corrosion resistance attributes allow for enhanced energy savings. For example, in the US there are legislated regulations that require the fuel consumption of the standard family car to be substantially reduced over the next two decades. One way of achieving this is to lower the overall weight of the vehicle via the use of a higher percentage of light-weight magnesium alloys. Not only does this save energy, but it also reduces greenhouse gas emissions. Within the next 8-10 years the amount of magnesium used in the automotive industry is expected to increase by at least 300%.

Modern life abounds with a variety of portable electronic and other consumer goods and here again the use of magnesium and its alloys is increasing.

Selected examples of the expanding applications of magnesium and its alloys include the following:

Aerospace Industry
Brake devices, gear boxes, helicopter transmission casings, turbine engines and wheels.

Automotive industry
Over 100 difference components, console brackets, engine blocks, gear boxes, seat supports, steering column assemblies, locks and brackets, support beams, transfer cases, transmission housings, valve covers and wheels.

Consumer Goods
Bicycle frames, camcorders, digital cameras, in-line skates, laptops, mobile (cell) phone and satellite phones, ski bindings, tennis racquets and TV cabinets.

The major companies involved in the aerospace and automotive industries, including Boeing, Airbus, Ford, General Motors, Volvo, VW and Toyota, all have a significant technical and commercial involvement in the development and application of high performance magnesium alloys in their industries.

HOW ARE MAGNESIUM METAL AND MAGNESIUM ALLOYS PRODUCED?

There are two basic methods for producing magnesium metal. The first involves the high temperature reduction of a suitable source of magnesium such as magnesite or dolomite, the other involves the electrochemical reduction of magnesium chloride. The magnesium chloride can be derived from sea water or other magnesium-containing brines or via the chemical processing of magnesite or dolomite. The high temperature reduction process is generally carried out on a batch basis, whereas the electrochemical route is carried out on a continuous basis.

Magnesium alloys are prepared by melting together the required amounts of alloying components with magnesium metal produced by one of the two production methods noted above. The molten alloys are subjected to appropriate refining techniques before being cast into ingots, the size and shape of which are matched to the requirements of the customer, such as a die caster producing components for the automotive industry.

In the past alloying and refining has been carried out via a so-called crucible-to-crucible technique. This is not particularly efficient, leading to relatively high metal losses and the generation of excessive quantities of product that does not meet the specifications for the high performance alloys, as demanded by most end users, especially those in the aerospace and automotive industries. The salt refining technology used by Quay Magnesium, on the other hand, yields products of the required specifications and is more energy efficient and has substantially lower metal losses.

WHAT IS THE CURRENT AND FUTURE DEMAND FOR MAGNESIUM AND MAGNESIUM ALLOYS?

Current world consumption of magnesium metal and magnesium alloys is in excess of 750,000 tonne per annum. Market projections indicate that consumption will increase rapidly to over 500,000 tonne per annum.

Of the various applications of magnesium and its alloys, die casting is the fastest growing sector of magnesium consumption. For example, die casting applications specific for the automotive industry are expected to increase by about 8 – 10% per annum over the next decade. 2008 estimates are 250,000 metric tonnes.

WHO ARE MAGNESIUM/MAGNESIUM ALLOYS PRODUCERS?

China is the largest producer and exporter of primary magnesium in the world today. The Chinese dominance of the industry is a reflection of its abundant primary sources of magnesium (magnesite and dolomite) and its relatively low-cost labour and energy. Currently there are around ninety (90) primary producers of magnesium in China, with all facilities using the high temperature reduction process commonly known as the Pidgeon process.

Other major producers include Dead Sea Magnesium, US Magnesium and a number of operations within the Russian Federation.

Quay Magnesium uses advanced salt refining technology to produce magnesium alloys of the highest quality that are expected to comply with, or exceed the current and anticipated future specifications for all of the high performance applications of magnesium alloys.

 

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