Isn't magnesium incredibly dangerous ?

Magnesium in bulk forms is very stable and near impossible to ignite accidentally.  As with many metals and materials, in finely divided form (powder or small shavings) magnesium can be readily ignited. We often explain it this way, grain silo’s have been known to ignite explosively,  yet few if any of us are fearful of buying or even toasting bread.  In the late 1940’s and early 1950’s DOW demonstrated how safe bulk forms of magnesium really are.  Below you can see a demonstration of cooking food on a magnesium griddle, placed on magnesium ingots. This is all being cooked with open gas flame.

Mag fireproof proof
Dow even produced a video short to demonstrate which forms were dangerous and which ones were safe.  On an annual basis more people are injured or killed by aluminum or titanium explosions. Of course aluminum production is far larger than magnesium production on an annual basis. Consider that magnesium is used in many notebook cases and has experienced far fewer industrial explosions in China than aluminum. Proper safety procedures are the only protection from metal powder fires. Magnesium fires burn very hot and very bright, but magnesium is not used to power rockets into space, this only possible with aluminum.

Doesn't magnesium corrode very easily ?

Magnesium is far more corrosion resistant than mild steel or iron. Since the late 1930’s it’s been known that high purity alloys offer low corrosion, in many cases lower than many cast aluminum alloys. Specific impurities are prime culprits in increase corrosion. These are Iron, Nickel and Copper, if these are kept to very low limits in the pure magnesium used to make alloys, significant improvements are had in resulting corrosion resistance.  If one considers magnesium like steel rather than aluminum it is easily understood that passivation or anodizing followed by coatings such as paint, of plating offers highly durable all weather performance.

Didn't they stop using magnesium for wheels because it is brittle ?

The history of light alloy wheels is one where for most of automotive history cast aluminum failed to offer ductility required to make a safe wheel. A few wheels makers in Germany, US and Italy finally improved aluminum casting technology to the point where it alloys safety and low costs. Still magnesium wheels offer higher ductility and safety than aluminum wheels, weather forged or cast. Corrosion protection often means polished finishes are not possible, but if painted these wheels out perform wheels made of any material including carbon fiber reinforced composites.

Isn't magnesium expensive ?

Browsing through the internet I see many claims of magnesium being more costly than Titanium, or so rare no one can work with it. In fact magnesium is about the same price per unit volume as aluminum, while processing magnesium can at times be more costly, these costs are on the order of 15-25% higher costs.  As for magnesium’s rarity, it is one of the few metal resources on earth to be considered inexhaustible. We often explain that magnesium is the affordable exotic, it offers strength to weight ratio’s in excess of most aluminum alloys and matches 6-4 titanium, only beryllium can beat specific stiffness.

What finishing systems can be used for magnesium ?

Dozens of magnesium finishing systems exist, most common are passivation, followed by a liquid or powder paint.  Systems of anodizing have existed since 1940’s often creating a hard and adherent coating, that is quite porous, this improved subsequent finishing systems such as paint or e-coating. Some very new lower cost higher performance finishing systems are now available, feel free to contact us for details on vendors and performance specifications.  

Plating can be applied to passivated or anodizing, chemically,  electrically applied or vacuum deposited. Cold enamels work very well, as do phenolic resins