Magnesium is produced by two principal methods: the silicothermic Pidgeon process and the electrolytic reduction of magnesium chloride (Dow process).
Magnesium is a lightweight structural metal produced primarily by thermic and electrolytic routes, with the Pidgeon process and chloride electrolysis being the most common methods. It exhibits a very low density and excellent strength‑to‑weight ratio, though challenges such as formability and corrosion resistance require alloying and surface treatments. Industrially, magnesium and its alloys are integral to automotive, aerospace, electronics, and chemical applications, where weight savings and specific mechanical properties drive their adoption.
Magnesium is produced by two principal methods: the silicothermic Pidgeon process and the electrolytic reduction of magnesium chloride (Dow process).
The Pidgeon process involves calcining dolomite to obtain MgO, mixing it with ferrosilicon (≈75–80 % Si), briquetting the mixture, and heating in retort‑type reduction furnaces under vacuum to distill magnesium vapor, which is then condensed into metal.
Electrolytic production entails dehydrating seawater or brine‑derived MgCl₂ to solid MgCl₂, dissolving it in molten chloride salts, and applying electrolysis to deposit magnesium at the cathode and chlorine gas at the anode.
Energy consumption for the Pidgeon process ranges from 17 to 20 kWh per kilogram of Mg, and it can emit up to 37 kg of CO₂ per kilogram of metal, driving research into microwave‑assisted reduction and alternative reductants to lower the environmental footprint.
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Magnesium has a density of 1.74 g/cm³, approximately one‑third lighter than aluminum, making it highly desirable for weight‑sensitive applications.
Its strength‑to‑weight ratio is comparable to many aluminum alloys, with precipitation‑hardened grades achieving tensile strengths of 130–300 MPa, and rare‑earth additions further improving high‑temperature creep resistance.
Chemically, magnesium forms a protective MgO layer in air, is less reactive with water than alkali metals, and ignites at around 630 °C, necessitating cover gases (e.g., SF₆) during smelting and coatings for corrosion protection.
Mechanically, magnesium alloys offer excellent machinability and vibration damping, though their hexagonal close‑packed crystal structure leads to strong anisotropy and limited formability at room temperature, often requiring elevated‑temperature processing.
Automotive: Widely used for high‑pressure die‑cast engine blocks, transmission housings, steering wheels, and chassis components to reduce vehicle weight and improve fuel efficiency.
Aerospace: Employed in helicopter transmission housings, jet‑engine frames, and structural components where every kilogram reduction enhances payload and performance; modern alloys extend use beyond engine parts into fuselage and interior structures.
Electronics: Magnesium’s light weight, EMI‑shielding capability, and thermal conductivity make it ideal for laptop casings, mobile phone frames, camera bodies, and other portable devices.
Other Applications: Biocompatible Mg alloys are explored for orthopedic implants and biodegradable devices; pure magnesium turnings serve as Grignard reagent precursors in organic synthesis; and MgO is used as a refractory lining in steel, glass, and cement industries.
Magnesium and its alloys combine exceptional lightness with competitive mechanical and chemical properties, driving their expanding role across industries focused on weight reduction and performance. For more detailed specifications or to discuss custom alloy solutions, contact us. As a trusted supplier of magnesium and specialty alloys, we deliver high‑quality materials tailored to your application needs.