Patent ID: 11913092
Assignee: CELLMO MATERIALS INNOVATION, INC.
Field: Materials, metallurgy (Chemistry)
Classification: CPC C  B | IPC B  C

Claim 7:
8. 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.