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The 3D morphological evolution of titanium foams as they undergo a two-step fabrication process is quantitatively characterized through x-ray micro- and nano-tomography. In the first process step, a Cu–Ti–Cr–Zr prealloy is immersed in liquid Mg, where Cu is alloyed with Mg while a skeleton of crystalline Ti–Cr–Zr is created. In the second step, the Mg–Cu phase is etched in acid, leaving a Ti–Cr–Zr foam with submicron struts. 3D images of these solidified Ti–Cr–Zr/Mg–Cu composites and leached Ti–Cr–Zr foams are acquired after 5, 10, and 30 min exposure to liquid Mg. As the Mg exposure time increases, the Ti–Cr–Zr ligaments grow in size. The tortuosity loosely follows the Bruggeman relation. The interfacial surface distribution of these Ti-foams is qualitatively similar to other nano-porous metal prepared by one-step dealloying. The characteristic length of the Mg–Cu phase and pores are also reported.
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