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

Claim 8:
9. 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.