Foam magnesium alloyMagnesium alloy possesses excellent mechanical propertiesMechanical properties, recyclability, and biodegradability, giving it vast potential for development across numerous fields. It is often referred to as the “green engineering material of the twenty-first century.” In this study, AZ91 magnesium alloyAZ91 magnesium alloy powder was used as the raw material, with urea serving as the pore-forming agent. The powder was pressed into cylindrical samples under 11 MPa of pressure, and the samples were sintered at 520 °C for 1.5 h with varying amounts of urea. Metallographic observations and mechanical propertyMechanical properties tests were conducted on the resulting samples. The findings suggest that an optimal urea content of 60 vol% results in favorable pore morphology and mechanical propertiesMechanical properties, with a stable stress plateau, making it a highly practical new green engineering material.