Abstract: This invention provides a high-strength and high-toughness metal which has strength and toughness each high enough to be put to practical use in expanded applications of magnesium alloys, and a process for producing the same. The high-strength and high-toughness metal is a magnesium alloy comprising a crystal structure containing an hcp-structure magnesium phase and a long-period layered structure phase. At least a part of the long-period layered structure phase is in a curved or flexed state. The magnesium alloy comprises a atomic % of Zn and b atomic % of Gd with the balance consisting of Mg.

Abstract: The invention relates to a process for conditioning material for pyrometallurgical conversion to magnesium, the process comprising carrying out de-su'fation of the material in a slurry to reduce sulfur content of the material; and carrying out de-ferration of the de-sulfated material in a slurry to reduce iron content of the material to produce a conditioned material suitable for pyrometallurgical conversion to magnesium.

Abstract: The present invention relates to an Mg—Al—Ca based master alloy for Mg alloys and to a production method therefor, and concerns an alloying master alloy used for magnesium or magnesium alloys. To this end, a feature of the invention is that, while the Ca:Al ration in the composition is maintained at between 7:3 and 1:9, based on percentages by weight in the alloy, a balance of Mg is added in an amount of up to 85% of the entire weight of the master alloy, based on percentage by weight. The production method comprises the steps of: preparing components of a master alloy by selecting a composition in which, while the Ca:Al ration in the composition is maintained at between 7:3 and 1:9, based on percentages by weight in the alloy, there is a balance of Mg in an amount of up to 85% of the entire weight of the master alloy, based on percentage by weight; sequentially melting Mg, Al and Ca; completely melting the components by applying an adequate amount of heat; and rapidly cooling the molten pool.

Abstract: What is proposed is a mixing and kneading machine (1) which is suitable, in particular, for continuously conditioning metals such as aluminium or magnesium for a subsequent die-casting operation. To this end, the mixing and kneading machine (1) has a worm shaft (3) which rotates and at the same time moves in translation in the axial direction in a housing (2). The temperature of both the housing (2) and the worm shaft (3) is controlled by means of a flowing gas in such a manner that the conditioned metal assumes a thixotropic state when it leaves the mixing and kneading machine (1).

Abstract: The present invention provides a preparation method of a metal matrix composite. The method comprises the following steps of: 1) pulverizing a solid carbon material to a micrometer size; 2) plastic deforming a metal matrix powder and dispersing the pulverized nanometer-sized carbon material into the metal matrix powder during the plastic deformation; 3) integrating the metal/carbon nano-material composite powder obtained in step 2) by using a hot forming process; and 4) heat treating the integrated bulk material at a predetermined temperature to form a composite having a metal-carbon nanophase, a metal-carbon nanoband formed by growth of the metal-carbon nanophase, or a metal-carbon nano-network structure formed by self-coupling of the metal-carbon nanoband.

Abstract: A process of producing magnesium metal includes providing magnesium carbonate, and reacting the magnesium carbonate to produce a magnesium-containing compound and carbon dioxide. The magnesium-containing compound is reacted to produce magnesium metal. The carbon dioxide is used as a reactant in a second process. In another embodiment of the process, a magnesium silicate is reacted with a caustic material to produce magnesium hydroxide. The magnesium hydroxide is reacted with a source of carbon dioxide to produce magnesium carbonate. The magnesium carbonate is reacted to produce a magnesium-containing compound and carbon dioxide. The magnesium-containing compound is reacted to produce magnesium metal. The invention also relates to the magnesium metal produced by the processes described herein.

Abstract: A method of using a protective gas composition comprising a fluorine-containing organic compound and a carrier gas for preventing a rapid oxidation or combustion of a molten magnesium/magnesium alloy alloy in a magnesium or magnesium alloy production process.

Abstract: A method of using a protective gas composition comprising a fluorine-containing organic compound and a carrier gas for preventing a rapid oxidation or combustion of a molten magnesium/magnesium alloy alloy in a magnesium or magnesium alloy production process.

Abstract: There is provided a protective gas composition for preventing combustion of a molten magnesium/magnesium alloy, containing a compound selected from the group consisting of 1,1,1,3,3-pentafluoropropane (HFC-245fa), 1,3,3,3-tetrafluoropropene (OHFC-1234ze), methyl 1,1,2,2-tetrafluoroethyl ether (HFE-254pc), which are fluorine-containing organic compounds, and mixtures thereof; and a carrier gas.

Abstract: Disclosed are cover gas compositions comprising fluoroolefins for impeding the oxidation of molten nonferrous metals and alloys, such as magnesium. The cover gas compositions can include at least one fluoroolefin and a carrier gas.

Abstract: A process of producing magnesium metal includes providing magnesium carbonate, and reacting the magnesium carbonate to produce a magnesium-containing compound and carbon dioxide. The magnesium-containing compound is reacted to produce magnesium metal. The carbon dioxide is used as a reactant in a second process. In another embodiment of the process, a magnesium silicate is reacted with a caustic material to produce magnesium hydroxide. The magnesium hydroxide is reacted with a source of carbon dioxide to produce magnesium carbonate. The magnesium carbonate is reacted to produce a magnesium-containing compound and carbon dioxide. The magnesium-containing compound is reacted to produce magnesium metal. The invention further relates to a process for production of magnesium metal or a magnesium compound where an external source of carbon dioxide is not used in any of the reactions of the process. The invention also relates to the magnesium metal produced by the processes described herein.

Abstract: In order to provide a method for supplying a cover gas which has sufficient preventive effects of oxidation-combustion and prevents cost-increase by containing a necessary and sufficient amount of fluoroketone in the cover gas which is supplied in a melting furnace of magnesium, the present invention provides a method for supplying a cover gas containing fluoroketone in a melt furnace to prevent oxidation and combustion of a melt of magnesium in the melt furnace, wherein the moisture concentration of gas in the melt furnace is measured, and the concentration of fluoroketone in the cover gas is adjusted to a range from 1/50 to 1/5 relative to the moisture concentration.

Abstract: A melting apparatus facilitates the melting of pieces of solid metal in a bath of molten metal (10). The melting apparatus comprises a device (18) having a lower portion (22), an upper portion (20), and a body portion (24) extending therebetween, introduction means for introducing the solid metal into the device (18) through the upper portion (20), flow inducing means (28) for inducing flow of molten metal through the device (18), and flow straightening means (38) for encouraging axial flow of motel metal through the device (18). The body portion (24) is formed with a plurality of apertures (36) therein and the device (18) is arranged, in use, with the lower portion (22) and the plurality of apertures (36) positioned within the bath (10) and the upper portion (20) positioned above the upper surface (12) of the molten metal bath (10).

Abstract: A magnesium-based casting alloy having good salt-spray corrosion resistance and improved creep resistance, tensile yield strength and bolt-load retention, particularly at elevated temperatures of at least 150° C., is provided. The inventive alloy comprises, in weight percent, 2 to 9% aluminum and 0.5 to 7% strontium, with the balance being magnesium except for impurities commonly found in magnesium alloys. A method of making an oxidation-resistant alloy melt, and the alloy melt prepared by such a method, are also provided. The alloy melt comprises magnesium as a primary alloying metal, and aluminum and strontium as secondary alloying metals, while the inventive method comprises: melting the alloying metals under an atmosphere of an inert gas selected from a mixture of carbon dioxide and sulfur fluoride gas, a mixture of nitrogen and sulfur dioxide gas, and combinations thereof.

Abstract: A method and apparatus of reclaiming magnesium from post consumer scrap and/or secondary magnesium turnings by feeding the post consumer scrap and/or secondary magnesium turnings into a rotary tray dryer and subjecting the post consumer scrap and/or secondary magnesium turnings to a controlled temperature and atmospheric environment to remove a substantial amount of liquid from the post consumer scrap and/or secondary magnesium turnings.

Abstract: In devices used for the direct conversion of heat into electricity, or vice versa, known in the art as thermoelectric power generators, thermoelectric refrigerators and thermoelectric heat pumps, the efficiency of energy conversion and/or coefficient of performance have been considerably lower than those of conventional reciprocating or rotary, heat engines and/or vapor-compression systems, employing certain refrigerants. The energy conversion efficiency of power generating devices, for example, aside from the hot and cold junction temperatures, also depends on a parameter known in the art as the thermoelectric figure of merit Z=S2&sgr;/k, where S is the thermoelectric power, &sgr; is the electrical conductivity and k is the thermal conductivity, of the material that constitutes the p-type, and/or n-type, thermoelements, or branches, of the said devices.

Abstract: The invention relates to a process for protecting a non-ferrous liquid metal from oxidation and from firing in a machine processing this metal or its alloys, consisting of disposing a gaseous mixture containing carbon dioxide at the surface of the non-ferrous metal. According to this process, the gaseous mixture is prepared by adding to the carbon dioxide an oxidising gas, argon and xenon only, this gaseous mixture having properties ensuring protection from the ambient atmosphere, and the proportion of carbon dioxide in this gaseous mixture ranging from 50% to 90% by volume.

Abstract: The present invention relates to a process for obtaining metals from oxides using shuttle alloys, particularly titanium metal from titanium dioxide in the form of illmenite rutile. The process can be adapted to obtain elemental metal or alloys of metals such as zirconium, chronium, molybdenum, tungsten, tantalum, lithium, cobalt and zinc. The process of the present invention comprises two stages, a first stage in which a metal oxide is reduced in the presence of primary shuttle material, which forms a shuttle alloy with the reduced metals, and a second stage wherein the reduced metal is separated from the shuttle alloy as a metal or alloy. Typically the primary shuttle material comprises bismuth or antimony or a mixture of the two and optionally lead. The reduction reaction may be carried out by chemical means or electrochemical means or by a combination of the two.

Abstract: The present invention provides a method for producing a metal vapor that includes the steps of combining a metal and graphite in a vessel to form a mixture; heating the mixture to a first temperature in an argon gas atmosphere to form a metal carbide; maintaining the first temperature for a period of time; heating the metal carbide to a second temperature to form a metal vapor; withdrawing the metal vapor and the argon gas from the vessel; and separating the metal vapor from the argon gas. Metal vapors made using this method can be used to produce uniform powders of the metal oxide that have narrow size distribution and high purity.

Abstract: The charge well of a metal melting furnace is provided with an internal cavity having a circular cross section when viewed from the top, preferably a cavity of cylindrical or conical configuration, and with a peripheral exit port located tangentially with respect to said cavity at a lower level thereof for exit of molten metal into the main chamber of the furnace. An inert gas bubble-actuated molten metal pump brings molten metal from a hotter section of the furnace, advantageously directly from the main chamber, and has its exit port located tangentially to the periphery of the cavity at an upper level thereof, thereby creating vortical flow of molten metal within the charge well for the more rapid and efficient melting of metal chips and scraps into the molten metal therein and for circulation of hotter molten metal throughout the furnace.

Abstract: A method for heating and/or melting a charge such as aluminum in a furnace using heat generated by combustion to radiatively heat the charge through a layer of protective gas wherein combustion reaction products generated by the combustion are exhausted from a lower level within the furnace, and, during melting, the protective gas layer has a higher upper boundary than during a subsequent heating period, enabling reduced NO.sub.x generation, lower fuel and oxygen consumption and reduced refractory corrosion by avoiding furnace gas flow through the high temperature upper furnace region.

Abstract: A process and apparatus are disclosed for recovering a non-ferrous metal, preferably aluminum and aluminum alloys, in molten coherent form from a charge of material to be processed containing the metal. The charge is introduced into a sealable furnace which is then sealed. The charge is agitated. A control parameter indicative of conditions inside said furnace is monitored and compared to a pre-determined first condition for the parameter. A heat source is operated to heat the charge until the control parameter reaches the first condition. The operation of the heat source is then stopped. A controlled amount of oxidizing agent and an inert carrier is then introduced into the furnace. The control parameter is monitored and compared to a predetermined second condition for the parameter. The flow of the oxidizing agent and the carrier is controlled to maintain the control parameter at about the second condition. The molten metal is subsequently removed from the furnace.

Abstract: A process for preparing a high strength magnesium alloy comprising heating a melt comprised of a base metal of magnesium, greater than 0.5% of lithium, and at least one alkali metal impurity selected from the group consisting of sodium, potassium, rubidium and cesium, the total alkali metal present in an amount greater than 5 ppm, to a temperature of about 50.degree. to 200.degree. C. above the melting point of alloy being refined in a vacuum for a sufficient time to reduce the aggregate concentration of alkali metal impurities in the melt to less than about 5 ppm as measured by GDMS.

Abstract: Method of treating rare earth metal-bearing scrap, waste or other material (e.g. Nd--Fe--B or Dy--Tb--Fe scrap) to recover the rare earth metal comprising melting the rare earth metal-bearing material, melting a Group IIA metal extractant, such as Mg, Ca, or Ba, in which the rare earth is soluble in the molten state, and contacting the melted material and melted extractant at a temperature and for a time effective to extract the rare earth from the melted material into the melted extractant. The rare earth metal is separated from the extractant metal by vacuum sublimation or distillation.

Abstract: Utilization of metal chips, especially scrap metal chips, particularly brass and aluminum, by introduction of the metal chips into a pool of molten metal of which they are formed or an alloy thereof, with minimization of fuel cost, heat loss, and minimal conversion of the metal at the surface of the molten metal pool to metal oxide, as well as an increase in the yield of utilizable metal from the remelting or recycling operation, by maintaining a non-oxidizing atmosphere at the surface of the molten metal pool and optionally utilizing vaporized residual impurities from chips being recycled such as oil, lacquer, or similar vaporizable impurity to assist in maintaining the non-oxidizing atmosphere, thereby permitting elimination of impurity-removal steps previously required for preparation of the chips for recycling by introduction into such a molten metal pool, and thereby also conveniently and simultaneously substantially reducing environmental pollution from vaporizable contaminants, fumes, and decomposition

Abstract: A and apparatus for melting and refining of magnesium and magnesium alloys is used both for melting of ingots and remelting of return metal. Metal is melted by pumping an overheated salt melt from a heating zone in a salt melt furnace and distributing it over the metal, which is placed in a basket above the liquid level in the furnace. The metal melts and is immediately removed from the basket without being further heated. A melt composition rich in calcium chloride with a content of calcium fluoride is preferably used.