Production, stability and properties of ultrafine MgAl2O4 (spinel) particles stabilized Mg–3Ca alloy foams

Abstract

The present work reports the synthesis and mechanical behavior studies of Mg–3Ca alloy foams stabilized by ultrafine MgAl2O4 (spinel) particles. The MgAl2O4 particles was created in-situ in the Mg–3Ca alloy melt through the reaction of Mg, Al and O. Foaming was done by adding dolomite (CaMg(CO3)2) as blowing agent in the melt. The foaming behaviour was studied for different MgAl2O4 content in Mg–3Ca and holding times (10 and 15 min). The study reveals that the presence of MgAl2O4 significantly influences the foaming behavior of Mg–3Ca alloy resulting in equiaxed cell structure, uniform cell size distribution, higher expansion in comparison to the Mg–3Ca alloy foam which contains only MgO and CaO. An in-depth phase and microstructural analysis were performed to investigate the particles present in the gas-solid interface of the foam that contributes to foam stabilization. The quasi-static compression studies of foams exhibited better compressive strength (≈3–11 MPa) and energy absorption capacity (≈1.3–5.7 MJ/m3) in comparison to the Mg foams reported in the literature. The ductility of the Mg foams was also measured and compared with that of existing aluminium foams.