Safe and Economically Efficient Use of Metal Working Fluids in Mechanical Processing of Magnesium Alloys

Magnesium, a light-weight metal, has been used as a construction material since the early days of the 20^th century. Excellent availability and low specific weight are the main benefits for applications in the aerospace and automotive fields. Because of a vast increase of Magnesium machining applications in the mobile equipment manufacturing industry over the last 10 years, there is an increasing demand for specially adapted cutting fluid systems for the machining of Magnesium parts. This paper will provide an overview on the latest research activities in Germany to develop new cutting fluid systems for a safe and economically efficient use of metal working fluids in mechanical processing of Magnesium alloys. Laboratory results and field applications with new innovative water-miscible cutting fluids are demonstrating that it is possible to control the huge problems of the past, such as hydrogen formation, emulsion split and corrosion. Based on experiences in the biggest european magnesium Machining project, the “Al/Mg Hybrid Crank Case” (Fig. 1), problems and solutions specific for large scale machining of Magnesium alloys with water-mixed cutting fluids are shown.