Abstract: A process based on molten salt electrolysis for producing pure rare earth metals is disclosed. This process is the direct electrolytic deposition of a rare earth metal such as neodymium, from a molten salt cell containing a mixture of electrolytes and a salt of neodymium, onto a liquid magnesium cathode forming an intermediate alloy. The intermediate alloy is distilled to isolate the neodymium metal. Also disclosed is a process for producing a pure neodymium/iron alloy wherein pure iron is added to the intermediate neodymium/magnesium alloy during the distillation step.

Abstract: A process for producing a magnesium-reactive metal alloy, for example a calcium-magnesium alloy, by electrodepositing the reactive metal from a molten salt bath containing a chloride of said reactive metal directly into a molten pool of magnesium.

Abstract: In a metallothermic process for reducing rare earth metal salts to produce pure rare earth metals and metal alloys, e.g. neodymium or neodymium/iron alloy for use in manufacturing neodymium/boron/iron permanent magnets, including adding pure metallic iron, such as iron flake, to a mixture of metal salt, such as neodymium chloride, and a reducing metal source, such as calcium/magnesium alloy, heating in a crucible in a preheated high temperature furnace with stirring to a temperature of 900 degrees C. under a flow of argon, separating the metal from the salt formed, and purifying the metal via distillation.

Abstract: Magnesium dialkyl phosphates capable of thickening or gelling nonpolar organic solvents are prepared by reacting a dialkyl acid phosphate with a magnesium oxide, hydroxide, or carbonate in organic solvent solution in the presence of a small amount of water within defined limits of time, temperature, mole ratios of reactants, and size of alkyl groups. The products are useful as thickening agents and vapor pressure depressants for nonpolar solvents.