This study investigates full liquid phase sintering as a process of fabrication parts from WE43 (Mg-4wt.%Y-3wt.%RE-0.7wt.%Zr) alloy using binder jetting additive manufacturing (BJAM). This fabrication process is being developed for use in producing structural or biomedical devices. Specifically, this study focused on achieving a near-dense microstructure with WE43 Mg alloy while substantially reducing the duration of sintering post-processing after BJAM part rendering. The optimal process resulted in microstructure with 2.5% porosity and significantly reduced sintering time. The improved sintering can be explained by the presence of Y₂O₃ and Nd₂O₃ oxide layers, which form spontaneously on the surface of WE43 powder used in BJAM. These layers appear to be crucial in preventing shape distortion of the resulting samples and in enabling the development of sintering necks, particularly under sintering conditions exceeding the liquidus temperature of WE43 alloy. Sintered WE43 specimens rendered by BJAM achieved significant improvement in both corrosion resistance and mechanical properties through reduced porosity levels related to the sintering time.

As the lightest structural metal and one of the most abundant metallic elements on earth, magnesium (Mg) has been used as an “industrial metal” for lightweighting in the transportation and electronics industries, in addition to other traditional applications in aluminum alloying, steel desulfurization and protective anodes. In recent years, research has shown significant potential for Mg to become a “technology metal” in a variety of new applications from energy storage/battery to biomedical products. However, global Mg production has shown steady but moderate growth in the last three decades. Mg applications as an industry metal are still limited due to some sustainability concerns of primary Mg production, as well as a number of technical issues related to the structural and corrosion performance of commercial Mg alloys. New Mg applications as an industrial or technology metal face tremendous technical challenges, which have been reflected in the intensified global research efforts in the last twenty years. This paper will review some past and present applications, and discuss future opportunities and challenges for Mg research and applications for the global Mg community.