Magnesium-based alloy foam

A method comprising:

• mixing a 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 comprising polystyrene and about 1-3 weight-percent dispersant comprising oligometric polyester powder;
• stirring or sonicating the suspension solution uniformly in a water bath for about 30-60 minutes to obtain a slurry solution;
• freeze casting the camphene-based magnesium alloy powder slurry solution;
• drying 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 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 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.

A method comprising:

• (i) mixing magnesium or magnesium alloy powder in a solution of liquid camphene to obtain a suspension solution containing about 3-6 weight-percent binder comprising polystyrene and about 1-3 weight-percent dispersant;
• (ii) stirring or sonicating the suspension solution uniformly in warm-water bath at above degrees Celsius for about 30-60 minutes to obtain a slurry solution;
• (iii) freeze casting the camphene-based magnesium or magnesium alloy powder slurry solution;
• (iv) 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
• (v) after drying, sintering the frozen green-body foam comprising the magnesium or magnesium alloy, 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,
• wherein the sintering the frozen green-body foam comprising the magnesium or magnesium alloy 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.