New insight into fabrication of shaped Mg-X alloy foams with cellular structure via a gas release reaction powder metallurgy route

Shaped Mg alloy foams with closed-cell structure are highly interested for a great potential to be utilized in the fields where weight reduction is urgently required.A powder metallurgical method,namely gas release reaction powder metallurgy route to fabricate Mg-X(X=Al,Zn or Cu)alloy foams,was summarized.The principles on shaped Mg-X foams fabrication via the route were proposed.In addition,the effects of alloying elements,sintering treatment and foaming temperatures on fabrication of shaped Mg-X alloy foams were investigated experimentally.The results show that the key to ensure a successful foaming of Mg-X alloy foams is to add alloying metals alloyed with Mg to form lower melting(<600℃)intermetallic compounds by the initial sintering treatment.The foaming mechanism of Mg-X alloy foams also has been clarified,that is,the low-melting-point Mg-based intermetallic compounds melt first,and then reactions between the melt and CaCO_(3),a foaming agent,release CO gas to make the precursor foamed and finally shaped Mg-X alloy foam with a promising cellular structure is prepared.This route has been verified by successful fabrication on shaped Mg-Al,Mg-Zn and Mg-Cu foams with cellular structure.