Letter 22834

Machining aluminum and magnesium castings on same CNC  

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As a high volume manufacturer of both magnesium and aluminum machined castings for the power tool industry we have always meticulously segregated aluminum parts, chips and coolant from magnesium. Both types of castings are processed in the same department on the manufacturing floor with seperate, custom built CNC, auto load/unload machining centers. It was recently proposed to reduce set up time, that the same CNC machines be used for both magnesium and aluminum castings. By running weekly batches of aluminum parts, then carefully cleaning chips out of the equipment and changing the coolant before running magnesium it would be a more cost effective operation. Is it a common practice in the high volume aluminum and magnesium machining industry to use the same CNC equipment for both materials on a daily basis? Is it safe? What problems might we encounter? What advice can you give me?

James Bolhuis
- Heber Springs, Arkansas, USA

Machining magnesium also requires a LARGE special fire extinguisher as regular ones have negligable effect as the Mg fire can make its own O2 from water. I believe that it requires Purple K extinguisher. Machine Mg on both, you now need another extinguisher (giant economy size). Overall, with the controls that you mentioned, my guess is that it would be ok. Aluminum dust and Mg dust are an explosive mixture, but I do not know the % mix or any special conditions.

James Watts
- Navarre, Florida

We use the same machine for both aluminum and magnesium. The important thing in our humble opinion might be obvious, never use cutting tools on magnesium that have been used on aluminum. Strict segregation of cutters is a great idea. I can not say I know all the reasons but I trust those who have come before us (Busk, Emley) who advised against it.

Josh Deetz
Berlin, Easter Cape, South Africa

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