Abstract: Employee #1 was using a scoop to pour flux onto small, fire-like flares that were shooting up approximately 14 in. above the rim of a pot containing molten magnesium alloy. He had just started walking away to get more flux from an open barrel when the flares erupted into a major blow. The explosion and resulting fire generated intense heat and Employee #1 sustained fatal burns. Employees #2 through #6 were in the vicinity of the pot at the time of the explosion. Employees #2, #3, and #5 sustained burns and were hospitalized; Employees #4 and #6 suffered from smoke inhalation but did not require hospitalization.