Author: Luxfer MEL Technologies

In this article, we compare two prominent conversion coatings: SurTec 650V and Iridite NCP. Both are renowned for their effectiveness in guarding against corrosion and their compliance with regulations. However, their applications, benefits, and suitability for different environments vary, making an informed choice essential for manufacturers.

We’ll guide you through the practical considerations of availability and cost, discuss the performance of each coating under rigorous conditions, and offer tailored technical advice from Luxfer MEL Technologies, a leader in magnesium alloy solutions. Whether you’re in aerospace, automotive, or another high-demand industry, understanding these options will help you make the best decision for your specific needs. Join us as we explore the future of conversion coatings and which coating will play a big role in sustainable manufacturing. They are not standalone solutions but integral components of a broader system that includes a suitable primer and topcoat to ensure optimal protection and performance (we’ll be releasing more on that soon!)

SurTec 650V offers a robust, visible blue-grey to yellow iridescent finish. This coating provides excellent corrosion protection and compliance with REACH, RoHS, and WEEE standards. It’s versatile in application, suitable for immersion, spray, or wipe methods, and can also be used to repair and refresh anodised coatings before painting.

SurTec 650V is highly regarded in the aerospace industry, meeting specifications of MIL-DTL-81706 and MIL-DTL-5541F. It is supplied as a concentrated liquid and serves as an efficient, low-resistance alternative to traditional hexavalent chrome passivation processes.

Iridite NCP is a chromium-free conversion coating, suitable for both spray and immersion applications. As a response to environmental directives such as ELV, RoHS, and WEEE, it does not contain hazardous substances like lead, cadmium, chromium, mercury, or PBB/PBDE compounds. This eco-friendly process yields a protective coating that provides corrosion resistance comparable to hexavalent chromates.

The Iridite NCP coating serves as an excellent base for paints, high-performance topcoats, powder paints, lacquers, or as a base for rubber bonding, without requiring aging or curing before topcoat application. Moreover, it features a wide operating range that accommodates various immersion times without compromising the coating’s quality or corrosion resistance.

Practical factors such as cost, availability, and lead times are crucial in choosing the right conversion coating. While both products perform excellently, their commercial availability and the cost-effectiveness of implementing them into existing production lines can vary, making it essential for manufacturers to evaluate both against their specific needs. With Iridite, curing time is eliminated, enhancing availability and efficiency, and importantly, it is a chromate-free solution, aligning with environmentally-conscious manufacturing practices.

When it comes to performance, both coatings excel in creating a strong foundation for further protective layers. They have been rigorously tested in environments simulating prolonged exposure to corrosive elements, with our salt fog tests demonstrating their effectiveness in protecting the underlying magnesium alloys (see image).

Luxfer MEL Technologies, a leader in magnesium alloy solutions, offers personalized technical advice to help customers choose the most suitable coating based on their specific application and environmental requirements. Their expertise ensures that each customer can optimise their coating process to reduce steps and maximise efficiency. We’d love to hear more about your applications and offer you full support throughout the process of turning magnesium materials into finished components.

As industries evolve away from chromate-based coatings in favour of more sustainable solutions, the focus shifts towards alternatives that not only meet new environmental regulations but also uphold stringent performance standards. Iridite NCP stands out as the choice, offering exceptional protection and adhesion properties without the use of chromates. For businesses aiming to adapt to stricter regulations while ensuring high product quality, prioritizing chromate-free alternatives like Iridite NCP is becoming increasingly essential.

Luxfer MEL Technologies is dedicated to supporting clients across aerospace, automotive, defense, oil & gas, and other sectors in this transition. By emphasizing solutions that reduce environmental impact without sacrificing performance.

At Luxfer MEL Technologies we specialise in machined magnesium components. We’d love to hear about your applications and discuss how we can help you to achieve a solution.

In aerospace engineering, the drive for more lightweight, durable, and efficiently manufactured materials is relentless. Luxfer MEL Technologies is leading this journey, crafting innovative solutions that are shaping the future of aerospace components. 

At a recent engagement, Paul Lyon FIMMM of the IOM3 Non-Ferrous & Light Metals Group Leadership Team, and Prem Mahendran of Luxfer MEL Technologies, examined the intricacies of magnesium alloy development. Their conversation underscored a crucial industry consensus: innovation within the aerospace sector hinges on the development of materials that are not only lightweight and robust but also produced through streamlined, efficient processes.

The aerospace industry is navigating several challenges—from the imperative of decarbonisation to the aftermath of supply chain disruptions triggered by the COVID-19 pandemic. The Paris Air Show in June 2023 spotlighted these challenges, revealing the underlying issue of protracted lead times in delivering essential aircraft components—an issue that persists despite the easing of pandemic-related disruptions. 

A prime exemplar of this innovation is Luxfer MEL Technologies’ Elektron®21 product, a magnesium alloy that’s applications within the aerospacesector are profound. Utilised by many OEMs, its applications range from magnesium castings to direct chill cast scenarios, embodying the essence of cutting-edge material application in aerospace. 

Luxfer MEL Technologies has been instrumental in addressing these challenges. The UK-based division has pioneered an alloy-specific manufacturing route, significantly curtailing the lead times for producing lightweight components—a transformative step that can reduce production timelines. 

Magnesium stands out as the lightest structural metal, offering an exceptional strength-to-weight ratio for weight-sensitive applications. The development of Luxfer MEL Technolgies’ Elektron® Magnesium alloys, known for their self-extinguishing properties and flame resistance, supportsthe material’s potential in aerospace applications, particularly in sand castings for new build programs. 

Luxfer MEL Technologies has innovated by machining components directly from large direct chill (DC) cast slabs, maintaining the mechanical properties synonymous with established sand-cast alloys. This process not only streamlines manufacturing but also opens avenues for rapid prototyping and the expedited production of aerospace components. 

The goal is clear: achieving specification properties in DC cast slabs that align with those of established sand-cast alloys. This approach minimises the risks associated with changing manufacturing routes and fosters interchangeability between castings and machined-from-solid slab components. 

The aerospace industry’s evolution is linked to advancements in material science. Luxfer MEL Technologies, with its pioneering work on magnesium alloys like Elektron® 21, is at the forefront of this transformation. By embracing innovation, enhancing manufacturing efficiencies, and ensuring material excellence, the company is not just responding to industry challenges—it’s shaping the future of aerospace engineering. 

Click Here to view the full article on the IoM3 website (courtesy Materials World March 2024).

In space exploration, where every ounce and kg matters, materials with exceptional strength-to-weight ratios are indispensable. Luxfer MEL Technologies has emerged as a leading developer of ultra-lightweight and robust magnesium alloys. This blog will explore how Luxfer MEL Technologies’ magnesium alloys are now the material of choice for space applications, offering unique advantages for spacecraft design and performance.

Luxfer MEL Technologies has successfully engineered magnesium alloys such as Elektron® 43 and Elektron® 21 that show an extraordinary strength-to-weight ratio. These alloys are significantly lighter than traditional materials like aluminum and steel, while still maintaining exceptional strength. In the weight-sensitive environment of space exploration, this property is crucial for reducing launch costs and improving overall spacecraft efficiency.

Reducing the weight of spacecraft is directly correlated with improved fuel efficiency. Luxfer’s magnesium alloys contribute to the development of lighter spacecraft, enabling more efficient fuel consumption during launch and travel through space. This not only translates to cost savings but also extends the range and capabilities of space missions.

Space is an unforgiving environment with extreme temperature variations. Luxfer’s magnesium alloys exhibit excellent thermal stability, with the ability to withstand both the intense heat generated during atmospheric re-entry and the frigid conditions of deep space. This thermal resilience ensures the structural integrity of spacecraft components, mitigating the risk of thermal stress and fatigue over time.

Our Magnesium Alloys are resistant to corrosion, a critical feature for prolonged space missions. The harsh conditions of space, including exposure to micrometeoroids and the vacuum of space, can compromise other traditional materials. Luxfer’s magnesium alloys offer exceptional corrosion resistance, ensuring the longevity and reliability of spacecraft components in the long term.

The unique properties of Luxfer’s magnesium alloys open up new possibilities for spacecraft design. Engineers can explore innovative and streamlined structures, taking advantage of the material’s strength and malleability. This flexibility in design can lead to more aerodynamic and efficient spacecraft, contributing to advancements in space exploration.

Magnesium is abundant in nature, and Luxfer’s commitment to sustainable practices makes our magnesium alloys an environmentally friendly choice. Using magnesium as a primary material reduces the reliance on scarce resources, making space exploration not only more efficient but also more sustainable in the long run.

Luxfer has actively collaborated with space agencies and private aerospace companies to integrate their magnesium alloys into various applications. This collaboration underscores the industry’s confidence in the reliability and performance of our material solutions.

Luxfers ultra-lightweight magnesium alloys are a game-changer in the field of space exploration. The combination of unmatched strength-to-weight ratio, thermal stability, corrosion resistance, and innovative design possibilities makes these alloys ideal for spacecraft applications.

As the demand for more efficient and cost-effective space missions continues to grow, Luxfer’s magnesium alloys are set to play a pivotal role in shaping the future of space exploration.

To find out more about introducing Magnesium Alloys in to your space exploration applications, fill in a short form below to get in touch with our sector manager, Rick Tonge.

In 2023, we shared the exciting news that Luxfer MEL Technologies are now offering a finished part service, taking our wide range of industry leading raw materials, and providing machined and coated finished Magnesium components.

Our Elektron® Finished Parts Team has been busy with setting the groundwork for our customers. Combining the exceptional knowledge of our technical department and the expertise of our subcontracting partners, our commitment is to find you the right application tailored to your specific requirements, as we understand the unique requirements for each individual project.

We know how crucial is to find the best recipe for you, whether you are a customer in the Oil & Gas, Automotive, Military or Aerospace industry, our expert team can help you to create the best product for your requirements, from design all the way to delivery of the finished component.

When it comes to coating applications, the industry has evolved, and so have we. Our pledge is to employ environmentally friendly coating systems. We exclusively work with chromate-free paints, ensuring compliance with REACH and RoHS regulations.

This commitment reflects our dedication to advancing our technologies to meet the diverse needs of our customers, whilst meeting our commitments in helping to create a more environmentally friendly world.

We understand the challenges associated with new development work, and the headache of choosing the most effective coating for your products whilst staying within your budget.

This is why we have decided to launch our coating trial, comparing our previous data with new test results, to guide you in making the most informed decision. Whether it’s a wet paint application, powder coating, PTFE or PEO coating you need to achieve your product capabilities, the variety of these coating applications is almost endless.

In collaboration with third-party experts, we will conduct a series of coating trials on our Magnesium alloys in the coming months. The trials will focus on Elektron® 21 for Aerospace, AZ31 for Military/Defense, and SoluMag® 1100 for Oil & Gas industries.

We recognise that product performance under various conditions – be it high or low temperature, humidity, altitude, or stress tests like thermal shock, salt spray, and drop tests – is crucial. Whether you aim to extend the lifespan of SoluMag®, ensure durability of AZ80 or AZ31 in military applications, or maximise the heat and corrosion resistance of Elektron® 21, we are here to help.

If you have already pinpointed the perfect type of coating for your Magnesium components, let us streamline your supply chain process.

Our one-stop-shop approach is designed to simplify and enhance your manufacturing journey. Let us know how we can assist you in achieving the highest standards for your products.

Find out more by visiting our dedicated Elektron® Finished Parts page, or get in touch with the team below for a consultation or quote.

Luxfer MEL Technologies offers innovative solutions to address the challenges associated with working with magnesium alloy materials. With a legacy of excellence spanning decades, Luxfer’s team of skilled engineers and partners have honed their craft, ensuring that every component meets the highest standards of quality and performance. 

Luxfer MEL Technologies boasts a wealth of experience in machining magnesium. This expertise is a result of years of dedicated research and hands-on application, giving us a profound understanding of the unique properties of this material. With this knowledge, we overcome common machining challenges, providing our partners with flawless components every time.

To guarantee top-notch results, Luxfer has forged partnerships with industry-leading suppliers, establishing best practices for machining magnesium alloys. This collaborative approach ensures that your magnesium parts are manufactured with precision and efficiency, saving you time and resources.

In addition to machining, Luxfer MEL Technologies leads the way in surface protection for magnesium materials. We collaborate with market-leading sub-contractors to offer the most advanced chromate-free magnesium alloy surface protection systems available today. These coatings not only provide outstanding corrosion resistance but also adhere to strict environmental regulations, aligning with the increasing demand for sustainable solutions.

Choosing Luxfer MEL Technologies for your machined magnesium components means choosing excellence, precision, and a commitment to sustainability. With decades of experience and a dedication to innovation, we are poised to elevate your projects to new heights. Let the magnesium experts take care of your component manufacture, and experience the Luxfer advantage today.

Magnesium alloys are a group of materials that consist mainly of magnesium (Mg) as the primary element. These alloys have a variety of properties that make them suitable for different applications.

One of the key properties of magnesium alloys is their low density. Magnesium has a density of only 1.74 g/cm3, which is significantly lower than other metals such as aluminum (2.7 g/cm3) and steel (7.8 g/cm3). This low density makes magnesium alloys an attractive choice for applications where weight savings are important, such as in the aerospace and automotive industries.

Another important property of magnesium alloys is their high strength-to-weight ratio. Magnesium alloys can have tensile strengths that are comparable to other structural metals such as aluminum and steel, but with a much lower weight.

Magnesium alloys are known for their excellent machinability, allowing them to be easily cast, forged, and extruded. They can be welded and brazed without difficulty, and exhibit good corrosion resistance. Additionally, magnesium alloys possess remarkable damping properties, making them valuable for applications requiring vibration isolation and noise reduction.

Luxfer has a developed a range of unique magnesium alloys that further enhance the advantages of magnesium materials.  Elektron® 43 alloy is a light, high strength wrought magnesium alloy for use at temperatures up to 250˚C. Designs in Elektron® 43 can be 20% to 30% lighter than a corresponding aluminium design. Elektron® 43 is available as rolled plate, forging feedstock and extruded bar, section and profile. Elektron® 43 is an optimised wrought evolution of the original casting alloy, Elektron® WE43.

The properties of Elektron® 43 mean it is well suited for use as feedstock material from which to machine high performance components, especially those associated with elevated temperature performance.

Magnesium alloys, with their low density and high strength-to-weight ratio, are a fascinating class of materials suitable for a wide range of applications, including aerospace, automotive, and electronics. Luxfer MEL Technologies’ Elektron® 43 alloy is a testament to the potential of magnesium alloys in helping to create a safer, cleaner and energy efficient world in various industries.

Discover how magnesium alloys can fit within your projects and get in touch with the team today.

In the realm of oil and gas industry innovations, SoluMag® HD has emerged as an exceptional product within the SoluMag® platform. Designed to address specific challenges in downhole applications, SoluMag® HD is a magnesium alloy known for its high ductility and controlled corrosion in aqueous chloride environments. This blog post will delve into the unique properties and applications of SoluMag® HD seamless tubes, shedding light on how they offer a cutting-edge solution for dissolvable frac plug components.

* Contact Luxfer representative for additional information

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* Contact Luxfer representative for additional information

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SoluMag® HD is an advanced magnesium alloy that stands out for its exceptional ductility. Unlike conventional dissolvable magnesium alloys, SoluMag® HD boasts an elongation rate exceeding 22% while maintaining its mechanical strength properties. This means that SoluMag® HD can undergo significant deformation without compromising its structural integrity, making it an excellent choice for demanding downhole environments.

To cater to diverse operational requirements, SoluMag® HD is available in multiple forms, including extruded tubes, rods, and bars. These seamless tubes are noteworthy for their exceptional performance in downhole applications. The high ductility of SoluMag® HD seamless tubes makes them a valuable asset in dissolvable frac plug components that require substantial expansion post-set.

SoluMag® HD seamless tubes offer a solution to downhole challenges by combining superior ductility with a well-controlled corrosion rate. The alloy’s high ductility allows it to expand significantly after setting, which is crucial for dissolvable frac plug components.

SoluMag® HD seamless tubes are lightweight, making them an ideal choice for applications that prioritize weight reduction. The reduced weight contributes to overall operational efficiency and cost-effectiveness.

The exceptional ductility of SoluMag® HD seamless tubes enables dissolvable frac plug components to expand effectively, providing optimal sealing and performance in downhole operations.

SoluMag® HD seamless tubes offer a ground-breaking solution to downhole challenges. Their high ductility, and controlled corrosion rate make them an ideal choice for dissolvable frac plug components that require substantial expansion post-set.

With the benefits of lightweight construction, enhanced durability, and increased performance, SoluMag® HD seamless tubes stand at the forefront of innovation, facilitating more efficient and reliable operations in the oil and gas sector. Want to find out more? Contact the team below.

Luxfer MEL Technologies is thrilled to announce that we will be exhibiting at the upcoming Paris Air Show. This highly anticipated biennial event brings together the brightest minds in the aviation industry to showcase the latest technologies, products, and services in the aerospace sector.

We at Luxfer MEL Technologies are excited to highlight our cutting-edge products and innovative solutions that have been developed specifically for the aerospace industry. Our wide range of magnesium alloy products, including our flagship alloy Elektron® 21.

One of our key products, our high-performance magnesium alloys, is lightweight and offers exceptional strength. These alloys are used in a wide range of aerospace applications, such as to reduce weight in fuselage structures, interior appliances and aero engine frames.

Our highly machinable, versatile magnesium alloys are also used in manufacturing gearboxes, covers and components, helicopter transmissions, electronic housings, flight control systems and aircraft wheels, to maximise fuel efficiency, additionally to take advantage of extruded magnesium durability. Our magnesium alloys are also highly resistant to corrosion, making them ideal for use in harsh environments.

At Luxfer MEL Technologies, we are committed to pushing the boundaries of what is possible in the aerospace industry. We are confident that our innovative products and solutions will help create safer, more efficient aircraft that meet the demands of today’s world.

We look forward to meeting with industry leaders, engineers, and aviation enthusiasts at the Paris Air Show and sharing our expertise and exciting products.

Would you like to arrange a meeting with a member of the team prior to, or at the show? Get in touch and we will reach out to you.

Experience the unparalleled performance of SoluMag® seamless tubes, meticulously designed for frac plug components. Our innovative SoluMag® products are available in both bar and seamless, extruded tube forms.

These exceptional tubes boast higher strength and impressive resistance to deformation and internal pressure, ensuring optimal performance even in the most demanding downhole environments during a typical frac operation.

Seamless tubes serve as the ultimate raw material for creating dissolvable frac plug components, thanks to their unique properties and versatility.

One of the standout benefits of SoluMag® seamless tubes is their adaptability in terms of customizable ODs and IDs. This flexibility in sizing options enables us to provide near net shapes tailored to individual frac plug components, ensuring a seamless fit for every application.

Moreover, SoluMag® seamless tubes are the go-to choice for plug components due to the consistent material properties present in every tube we produce, guaranteeing exceptional quality and reliability.

By choosing SoluMag® seamless extruded tubes for your components, you’ll reap the benefits of working with one of the lightest and most robust structural metal alloys available.

• Energy efficiency: Requires only about 55% of the power needed for aluminum machining
• Speedy processing: Facilitates high cutting speeds, large feed rates, and greater depths of cut
• Well-broken chips: Results from the superior free-cutting qualities of SoluMag
• Prolonged tool life: Reduced tool wear ensures extended tool longevity

As part of our commitment to sustainability, Luxfer is proud to offer a drum pick-up and recycling service for your SoluMag chips.

Trust in SoluMag® seamless tubes for your frac plug components and experience the difference that quality, innovation, and precision can make.