Morphology, microstructure, compressive behavior, and biocorrosive properties of magnesium or magnesium alloy foams allow for their use in biodegradable biomedical, metal-air battery electrode, hydrogen storage, and lightweight transportation applications. Magnesium or Mg alloy foams are usually very difficult to manufacture due to the strong oxidation layer around the metallic particles; however, in this invention, they can be synthesized via a camphene-based freeze-casting process with the addition of graphite powder using precisely controlled heat-treatment parameters. The average porosity ranges from 45 to 85 percent and the median pore diameter is about a few tens to hundreds of microns, which are suitable for bio and energy applications utilizing their enhanced surface area. This invention based on powder-slurry freeze-casting method using camphene as a volatile solvent is also applicable for other metal foams such as iron, copper, or others to produce three-dimensional metal foams with high strut connectivity.

A three-dimensional metallic foam is fabricated with an active oxide material for use as an anode for lithium batteries. The porous metal foam, which can be fabricated by a freeze-casting process, is used as the anode current collector of the lithium battery. The porous metal foam can be heat-treated to form an active oxide material to form on the surface of the metal foam. The oxide material acts as the three-dimensional active material that reacts with lithium ions during charging and discharging.

Using metal foams for the electrode of secondary lithium battery, preparing method thereof, and secondary lithium battery including the metal foam. A metal foam is used in an electrode of secondary lithium battery where the surface and the inner pore walls are coated with the active materials, a method of manufacturing such metal foam, and secondary lithium battery including the metal foam.

Using metal foams for the electrode of secondary lithium battery, preparing method thereof, and secondary lithium battery including the metal foam. A metal foam is used in an electrode of secondary lithium battery where the surface and the inner pore walls are coated with the active materials, a method of manufacturing such metal foam, and secondary lithium battery including the metal foam.

A three-dimensional metallic foam is fabricated with an active oxide material for use as an anode for lithium batteries. The porous metal foam, which can be fabricated by a freeze-casting process, is used as the anode current collector of the lithium battery. The porous metal foam can be heat-treated to form an active oxide material to form on the surface of the metal foam. The oxide material acts as the three-dimensional active material that reacts with lithium ions during charging and discharging.

This disclosure provides systems, methods, and apparatus related to freeze casting. In one aspect, a method comprises providing an apparatus. The apparatus comprises a container and a cooling surface. A bottom of the container comprises a wedge. The wedge comprises a first substantially planar surface and a second substantially planar surface with an angle between the first and the second substantially planar surfaces. An interior bottom of the container comprises the second substantially planar surface. The cooling surface is in contact with the first substantially planar surface. A slurry is deposited on the second substantially planar surface, the slurry comprising a plurality of particles in a liquid. The cooling surface is cooled to cool the slurry at a specified cooling rate.

Using metal foams for the electrode of secondary lithium battery, preparing method thereof, and secondary lithium battery including the metal foam. A metal foam is used in an electrode of secondary lithium battery where the surface and the inner pore walls are coated with the active materials, a method of manufacturing such metal foam, and secondary lithium battery including the metal foam.

Using metal foams for the electrode of secondary lithium battery, preparing method thereof, and secondary lithium battery including the metal foam. A metal foam is used in an electrode of secondary lithium battery where the surface and the inner pore walls are coated with the active materials, a method of manufacturing such metal foam, and secondary lithium battery including the metal foam.

A method of manufacturing a porous part includes controlled freeze casting of a slurry. After freezing, a solvent in the slurry is removed by sublimation and the remaining material is sintered to form the porous part. Spatial and temporal control of thermal conditions at the boundary and inside of the mold can be controlled to create parts with controlled porosity, including size, distribution, and directionality of the pores. Porous parts with near-net-shape from ceramics, metals, polymers and other materials and their combinations can be created.

Morphology, microstructure, compressive behavior, and biocorrosive properties of magnesium or magnesium alloy foams allow for their use in biodegradable biomedical, metal-air battery electrode, hydrogen storage, and lightweight transportation applications. Magnesium or Mg alloy foams are usually very difficult to manufacture due to the strong oxidation layer around the metallic particles; however, in this invention, they can be synthesized via a camphene-based freeze-casting process with the addition of graphite powder using precisely controlled heat-treatment parameters. The average porosity ranges from 45 to 85 percent and the median pore diameter is about a few tens to hundreds of microns, which are suitable for bio and energy applications utilizing their enhanced surface area. This invention based on powder-slurry freeze-casting method using camphene as a volatile solvent is also applicable for other metal foams such as iron, copper, or others to produce three-dimensional metal foams with high strut connectivity.