CPC C22C 1/08 (2013.01) [B22F 1/06 (2022.01); B22F 1/10 (2022.01); B22F 3/11 (2013.01); B22F 3/222 (2013.01); C22C 23/00 (2013.01); C22C 23/02 (2013.01); C22C 23/04 (2013.01); C22C 23/06 (2013.01); B22F 3/10 (2013.01); B22F 2202/01 (2013.01); B22F 2301/058 (2013.01); B22F 2998/10 (2013.01); C22C 1/087 (2023.01)] | 9 Claims |
1. A method comprising:
mixing magnesium or magnesium alloy powder having a particle size from about 36 microns to 45 microns in a solution of camphene to obtain a suspension solution containing about 3-6 weight-percent binder and about 1-3 weight-percent dispersant;
stirring or sonicating the suspension solution uniformly in water bath for about 30-60 minutes to obtain a slurry solution;
freeze casting the camphene-based magnesium or magnesium alloy powder slurry solution;
drying, via sublimation, camphene, a frozen green-body foam, by placing the frozen green-body foam in an air hood for about 3-7 days or in a freeze dryer for about 24-48 hours; and
after drying, sintering the frozen green-body foam comprising the magnesium or magnesium alloy, wherein the sintering comprises a two-step sintering process comprising burning of the binder and dispersant at about 300-450 degrees Celsius for about 3-5 hours, and sintering of the frozen green-body foam at about 500-650 degrees Celsius for about 3-10 hours in argon atmosphere, and
after sintering, a three dimensionally connected magnesium or magnesium alloy foam is produced of at least one of Mg—Al, Mg—Zn, Mg—Al, Mg—Mn, Mg—Si, Mg—Cu, Mg—Zr, or Mg-rare earth element, or any combination thereof.
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