In machining of magnesium alloys, waterbase cutting fluids can be effectively used to eliminate the buildup formation and minimize the possibility of chip ignition. After that, the machining of magnesium is covered addressing general issues and more specific particularities of magnesium machining, such as the. Appropriate submissions to the journal of magnesium and alloys include studies that investigate scientific andor engineering factors that affect the metallurgy. The main concern in machining magnesium alloy is the danger of fire ignition when dry cutting.
Applications applications for magnesium alloys can be found in aerospace and motorsport sectors where strength combined with reduced weight are of critical importance. Magnesium check out our magnesium cast services denver. If when necessary to use coolant, a light mineral oil will suffice. Heavyduty emulsifiable oil for moderate to difficult machining and grinding applications. I have seen 5 fires on machines running oil and ti, but never got hot enough to get the ti going well. Cast alloys containing copper, magne sium, or zinc as the principal alloying ele ments impose few. It is unique for its low density, high column loading per unit weight and high specific modulus. The small chips and fine dust generated during cutting are also highly flammable and pose a serious fire risk if not properly handled. Magnesium alloys are the easiest of all structural metals to machine. Transicut oils are nonstain, transparent cutting oils intended for highspeed automatic screw machining and simple turning.
This article focuses on the factors that affect the machining of magnesium. Phosphor bronzes, or tin bronzes, are alloys containing copper, tin and phosphorous. In addition, lubricating oil, hydraulic oil, guide oil, and spindle oil used in machine tools are mostly flammable liquids, and the general oil storage capacity is not small. Icc 2825c is highly recommended for use as a turning, drilling. Magnesium alloys have a hexagonal lattice structure, which affects the fundamental properties of these alloys. Oldani b a department of metallurgical engineering, national technological university, regional faculty ca. This product obtains extreme pressure lubricity without using sulfurized fats. Magnesium is another common choice for a metal casting material. It is easy to mix and protects machines and parts from corrosion and staining.
Ati supplies aerospacequality, sonicconfiguration machining services, specializing in material preparation and rough and finish machining on components in a wide variety of sizes and shapes. Possibilities of recovering az91 magnesium alloy from machining shavings contaminated with oil, through their fusion with argon gas protection r. Az80a may be given the t6 solution heat treatment, followed by artificial aging to provide maximum creep stability. We maintain a wide range of machining capabilities. These can be further shaped using forging, pressing, bending or simply machining from solid.
Aluminum alloys cast, wrought, strain hardenable, and heat treatable are the four major classifica tions of aluminum alloys. Problems and hazards when machining magnesium and its alloys. This makes durasol a an excellent choice for use on steels with moderate machinability ratings, aluminum, copper alloys, and aerospace alloys. Machining is an industry leader in the production of parts machined from magnesium. Magnesium machining is normally done without any coolant. Magnesium alloys are mixtures of magnesium with other metals called an alloy, often aluminum, zinc, manganese, silicon, copper, rare earths and zirconium. Exceptionally fine finishes can be obtained so that grinding to improve the finish usually is unnecessary. It is possible to achieve a high cutting speed for magnesium alloy, there are however, concerns that with an increase in cutting speed, there may be serious flank buildup fbu due to. Hazards of machining magnesium practical machinist. Texaco almag oil is recommended for light duty machining and grinding operations on ferrous and nonferrous metals. Manganese bronzes alloys can operate under very high loads and speeds.
Magnesium alloys are noted for low weight, high strength to weight ratio, exceptional damping capacity and ease of machining. Magnesium replacement of aluminum magnesium applications in the powertrain perceived barriers to powertrain applications for magnesium high cost of creepresistant alloys for 125 o c oem reluctance to cast or machine mg concerns about corrosion behavior coolant, galvanic, and atmospheric limited powertrain design experience. The uniqueness of the magnesium alloys is illustrated in. If it were me id be tempted to mix the magnesium chips with an inert filler such as dry sand so that each magnesium alloy chip is. Trim e806 does not tarnish the most sensitive magnesium alloys even after relatively long exposure times plus it is impervious to magnesium salt buildup in the sump something which splits normal emulsions in a. However, auxiliary collection devices hamper both tool changes and machine high speed movements. Fire may occur when the melting point of the alloy 400600 degrees celsius is exceeded during machining. Introduction to magnesium alloys asm international. The product is primarily designed for machining magnesium alloys used in the aerospace, automotive and general industry sectors. Tensile and yield strengths are generally lower than for aluminum, particularly at elevated temperatures. The high affinity of magnesium alloys az91d for oxygen is also one of the disadvantages that lead to the oxidation and ignition of chips ultimately. Some other properties are good machinability, high specific toughness and. This brochure discusses the machining of magnesium alloys on the way from cast part to finished product. Magnesium is recognized as being the lightest structure metal.
Magnesium alloys are best known for their low density, which results in forgings with very low weight. Most machining of magnesium alloys is done dry,but cutting fluids sometimes are used for cooling the work. Hazards of machining magnesium a new customer has a few jobs to quote, machining magnesium parts. Gearbox components, pistons and casings are typical applications. A research consortium has developed a novel way to extract magnesium particles out of the machine by vacuuming them through a. Developing a safer way to machine magnesium machining magnesium is risky business, as the chips and dust generated are flammable. Bronze, brass, and copper alloys national bronze mfg. They have excellent lubricity and antiweld properties and assist in extending tool life and producing a quality finish on machined parts. The use of oil based coolants reduces, but doesnt eliminate, the fire risk. Hydro magnesium provides technical support to its customers to contribute to superior quality in the finished products.
Besides excellent mechanical qualities, these alloys have good corrosion resistance. Emphasis has been placed on practical tool and machining data. Possibilities of recovering az91 magnesium alloy from machining shavings contaminated with oil, through their fusion with argon gas protection. We have experience with advanced aerospace metals such. Primary recommended for low carbon steels, free machining steels and nonferrous alloys.
The az80a alloy has greater strength than az61a and requires the slowest rate of deformation of the magnesiumaluminumzinc alloys. When innovative industries choose to pioneer in the use of new alloys, they call cox manufacturing for a very traditional outcome. It is formulated for stability in extremely high water hardness, making it suitable for some magnesium machining applications. Highspeed tools or carbide tipped tools are preferred for the machining of magnesium.
In this sense, an approximation to the properties of magnesium, magnesium alloys and metal matrix composites of magnesium, and some applications are presented to give a general overview of magnesium. Hysol amg contains a high level of ep additives, primarily to improve performance on heavy duty grinding and machining of ferrous metals. De102007004325a1 cooling lubricant for the aqueous. Magnesium mg alloys, the lightest of structural materials on the earth, possess great potential to be used in important sectors such as automobiles, aerospace, and biomedical applications. I want to know what precautions i should be taking when machining magnesium alloy. Magnesium alloys can be shaped into plate by rolling and extruded into both solid and hollow profiles. Machining is an industry leader in the production of parts machined from aluminum. Therefore, magnesium alloys should be specially inspected before precision parts processing, and whether there is oil leakage at each position of the machine tool. Plastic deformation of the hexagonal lattice is more complicated than in cubic. What joe miranda advised should prevent any problems as it. It is an active sulfurized product and is not suitable for nonferrous metals like brass, copper, bronze, aluminum and magnesium alloys. The present invention relates to an oilcontaining, watermiscible emulsion concentrate containing i an oil component, ii an emulsifier system comprising a ethoxylates propoxylates of fatty alcohols having 8 to 18 carbon atoms in the alcohol with 2 to 6 ethylene oxide units and 4 to 8 propylene oxide units and b fatty alcohols and or fatty alcohol propoxylates having 12 to 24 carbon. Magnesium replacement of aluminum cast components in a.
Magnesium is the third most commonly use structural metal after iron and aluminium and historically has been used in applications including german aircraft during world war 1. They are sometimes alternatives to aluminum when low weight is essential. It is excellent for aluminum, magnesium and their alloys. In machining of magnesium alloys,cutting fluids provide far smaller reductions in friction than they provide in machining of other metals and thus are of little use in improving surface finish and tool life. It is particularly suited for the machining of magnesium where the use of a waterbased fluid could create a fire hazard. Forging billet extruded magnesium luxfer mel technologies. Various heat treatments are used to attain maximum strength and machining of most magnesium alloys is excellent. Therefore for safe and ecologic machining of magnesium specific techniques are used. For example, tools used for the hsm of magnesium alloys are coated with different materials to reduce reactivity. Pdf possibilities of recovering az91 magnesium alloy. The journal of magnesium and alloys provides an international medium for the publication of theoretical and experimental studies in magnesium science and engineering.
Machining of magnesium and magnesium alloys machining. The usual practice is to employ high cutting speeds with relatively coarse feeds and deep cuts. In addition, the magnesium particles mixed in oil cant be recycled, and the machined parts would require extensive cleaning to remove oil residue. Magnesium alloys, machining, turning, milling, drilling introduction magnesium and its alloys are the lightest as compared with all other metals. Never use water based coolant because of the risk of any reaction with the chips during storage. Machining is a leader in the manufacturing of parts produced from nickel alloys. Back in the 70s there was a fire from the machining of magnesium at wentworth institute in boston. Featured straight oil machining and grinding coolants.
Machining of zinc alloy diecastings is mostly done without a lubricant. Uninet 4 is an economical neat cutting oil blended with chlorinated and sulfurized ep additives for machining applications of free cutting, stainless and alloyed steel. Possibilities of recovering az91 magnesium alloy from. High speed machining of magnesium and its alloys request pdf. Magnesium alloys are readily machined and with relatively low power consumption per cubic inch of metal removed. High stiffnesstoweight, castability, machinability, and excellent damping are desirable properties of magnesium alloys that factor into the material selection process. To develop maximum properties, both az80a and zk60a are heat treated to the artificially aged t5 condition. Ati supplies precision machining services to the aerospace industry, specializing in finish machining operations on. For surface grinding, when a fine finish is desirable, a lowviscosity mineral oil may be used. For magnesium alloys, powerful cutting can be performed at high cutting speeds and large feed rates, so that the number of machining hours can be reduced. Cutting magnesium on the band saw practical machinist. It discusses chip formation and distortion due to thermal expansion, cold work, and clamping and provides information on magnesium matrix composites.
676 472 462 1467 607 1212 1098 326 595 1491 109 928 863 759 422 692 1333 1089 1082 54 1456 529 1100 1436 574 226 1178 446 1407 501