Abstract: An apparatus and method of uniformly heating, rheologically softening, and thermoplastically forming metallic glasses rapidly into a net shape using a rapid capacitor discharge forming (RCDF) tool are provided. The RCDF method utilizes the discharge of electrical energy stored in a capacitor to uniformly and rapidly heat a sample or charge of metallic glass alloy to a predetermined “process temperature” between the glass transition temperature of the amorphous material and the equilibrium melting point of the alloy in a time scale of several milliseconds or less. Once the sample is uniformly heated such that the entire sample block has a sufficiently low process viscosity it may be shaped into high quality amorphous bulk articles via any number of techniques including, for example, injection molding, dynamic forging, stamp forging, and blow molding in a time frame of less than 1 second.

Abstract: In Cu-based bulk amorphous matrix composite materials, comprising a Cu-based amorphous alloy containing high fusion point element(s) selected from a group of Ta, W or combination thereof, wherein the high fusion point element(s) has(have) a shape of crystalline grain and is(are) dispersed around a Cu-based amorphous matrix. Cu-based bulk amorphous matrix composite materials have the composition expressed as the following Chemical formula 1; CuaZrbTicRd??[Chemical formula 1] where R is Ta, W or combination thereof, a, b, c and d are atomic weight ratio, a+b+c+d equals 100, a, b, c, and d have the range of 45?a?65, 10?b?35, 5?c?30, and 5?d?10, respectively.

Abstract: The present disclosure concerns (i) a hypodermic needle composed of a metal alloy, wherein the metal alloy is in a predominantly amorphous form, said amorphous form of said metal alloy having a glass transition temperature (T 9 ) in the range of 50-6500 C, (ii) methods for the manufacture of such injection needles by casting or moulding an amorphous alloy, and (iii) a method of safely disposing hypodermic needles.

Abstract: A composite material based on a bulk metallic glass is disclosed. In an amorphous alloy phase forming a substantially continuous matrix, a second phase comprising graphite particles is embedded. The alloy is preferably zirconium based. The particles may have a carbide surface layer, which may be formed phase comprising carbide particles may also be present. The composite material has high plasticity, high yield strength, good elasticity and low coefficient of friction, which renders it a good candidate for applications like joints, frictional bearings or Springs.

Abstract: A method of making composites of bulk-solidifying amorphous alloys, and articles made thereof, containing at least one type or reinforcement material, wherein the composite material preferably comprises a high volume fraction of reinforcement material and is fully-dense with minimum porosity are provided.

Abstract: The present invention relates to the addition of niobium to iron based glass forming alloys and iron based Cr—Mo—W containing glasses. More particularly, the present invention is related to changing the nature of crystallization resulting in glass formation that may remain stable at much higher temperatures, increasing the glass forming ability and increasing devitrified hardness of the nanocomposite structure.

Abstract: A method of forming a single crystal in a thin film by progressively rapidly heating (and cooling) a narrow band of amorphous material. The amorphous thin film may be of shape memory alloy such as TiNi or CuAlNi. Heating may be accomplished by a line-focused laser beam. The thin film may be formed by sputter deposition on a substrate such as silicon. The thin film crystal that is formed has non-isotropic stress/strain characteristics, and very large recoverable strain in a preferred direction. The single crystal SMA exhibits greater strain recovery; Constant force deflection; Wider transition temperature range; Very narrow loading hysteresis; and Recovery that is repeatable & complete. Single Crystal SMA is manufactured by pulling a single crystal from melt, a method similar to that used by the semiconductor industry to fabricate silicon boules. This process enables manufacture of materials that approach theoretical limits.

Abstract: An alloy, which can be used in a microwire, contains 26 to 52 weight % Fe; 26 to 52 weight % Co; 3.0 to 38.0 weight % Ni; at least one selected from the group consisting of 1.0 to 8.0 weight % V, 1.0 to 8.0 weight % Cr, 1.0 to 8.0 weight % Zr, 1.0 to 8.0 weight % Dy and 1.0 to 8.0 weight % Nb; at least one selected from the group consisting of 2.0 to 8.3 weight % Si and 2.0 to 8.3 weight % B; and at least one selected from the group consisting of 0.2 to 1.6 weight % Ce, 0.2 to 1.6 weight % La and 0.2 to 1.6 weight % Y. When cast in a microwire, the alloy can be substantially amorphous.

Abstract: Mechanical hooks made of bulk-solidifying amorphous alloys, wherein the bulk-solidifying amorphous alloys provide ruggedness, durability, higher service loads, excellent resistance to chemical and environmental effects, and low-cost manufacturing are provided. In addition, methods of making such mechanical hooks from bulk-solidifying amorphous alloys are also disclosed.

Abstract: A method of forming in-situ composites of metallic alloys comprising an amorphous phase are provided. The method generally comprising the steps of transforming a molten liquid metal at least partially into a crystalline solid solution by cooling the molten liquid metal down to temperatures below a “remelting” temperature, then allowing the solid crystalline metal to remain at temperatures above the glass transition temperature and below the remelting temperature such that at least a portion of the metal remelts to form a partially amorphous phase in an undercooled liquid, and finally subsequently cooling the composite alloy to temperatures below the glass transition temperature.

Abstract: Stents made of bulk-solidifying amorphous alloys and methods of making such stents are provided.

Abstract: A method of forming bulk metallic glass engineering materials, and more particularly a method for forming coarsening microstructures within said engineering materials is provided. Specifically, the method forms ‘designed composites’ by introducing ‘soft’ elastic/plastic inhomogeneities in a metallic glass matrix to initiate local shear banding around the inhomogeneity, and matching of microstructural length scales (for example, L and S) to the characteristic length scale RP (for plastic shielding of an opening crack tip) to limit shear band extension, suppress shear band opening, and avoid crack development.

Abstract: A nano-crystalline steel sheet and a method of making a nano-crystalline steel sheet are provided. The nano-crystalline steel sheet may be produced by supplying a liquid metallic glass forming alloy to counter-rotating casting rolls. The liquid alloy may form partially solidified layers on each of the casting rolls. The partially solidified layers may then be pressed together by the counter-rotating casting rolls to form a sheet. The twin casting roll method may provide a sufficiently high cooling rate during solidification of the alloy to create a nano-crystalline microstructure.

Abstract: A method for treating a component comprising a metallic or ceramic material with a crystalline, semi-crystalline or amorphous structure. According to the method, to caseharden the component, at least part of the surface of the component is exposed to an oil jet, while the temperature of the oil and/or the component is regulated. Also disclosed is a device for carrying out the method.

Abstract: Composite phase structure of early transition metal-based metallic alloys, including those of crystalline, quasicrystalline and amorphous phases, can be obtained in a controllable way upon direct (in-situ) cooling (solidification) of the alloy, realized either by adjusting the alloy compositions at a fixed cooling rate or by changing the cooling rates for a given alloy composition. Some embodiments are based on the addition of later transition metals, mainly of Cu with Ni or Fe with Co in early transition metal based (mainly Ti and Zr or Hf and Nb) metallic alloys. If cooling rate is on the scale of 103° C./s, a wholly amorphous structure is obtained for most of the compositions. At reduced cooling rates, composite structures with different kinds of phases can be achieved, as illustrated graphically in FIG. 1. Nickel addition promotes the formation of quasicrystalline phases, especially for Ti-rich alloy compositions with beryllium.

Abstract: Spherical particles having curvatures larger than those of irregularities, crystal grain boundaries, lattice defects or the like (referred to collectively as irregularities, hereinafter) on the surface of a conductive metal material are ejected at high speeds to make the particles collide against the surface of the conductive metal material, thereby repeatedly causing rapid melting and cooling at the minute points of impact of the particles, thereby changing the surface into amorphous. Then, spherical particles having curvatures smaller than those of irregularities on the surface subjected to the treatment described above collide against the surface, thereby changing the surface into amorphous and planarizing the surface.

Abstract: High strength, high ductility aluminum base alloys containing from 3 to 18.5 atomic percent nickel and 3 to 14.0 atomic percent yttrium, said alloy being in the devitrified state and containing less than 40 percent intermetallic phases.

Abstract: Compositions for forming Au-based bulk-solidifying amorphous alloys are provided. The Au-based bulk-solidifying amorphous alloys of the current invention are based on ternary Au—Cu—Si alloys, and the extension of this ternary system to higher order alloys by the addition of one or more alloying elements. Additional substitute elements are also provided, which allow for the tailoring of the physical properties of the Au-base bulk-solidifying amorphous alloys of the current invention.

Abstract: Amorphous Fe- and Co-based metal foams and methods of preparing the same are provided. The Fe- and Co-based foams are prepared from Fe- and Co-based metal alloys of low hydrogen solubility having an atomic fraction of Fe or Co greater than or equal to the atomic fraction of each other alloying element. A method for producing the Fe- and Co-based foams includes the in situ decomposition of a hydride in a molten Fe- or Co-based alloy.

Abstract: The invention includes a method for producing high-density composites of metallic glass alloy powders in combination with a refractory metal powder, and includes related methods for producing metallic glass alloys. The invention, in one aspect, employs a system of monitoring the temperature and hot isostatic pressing conditions during the consolidation of metallic compositions in order to produce higher densities and materials of a larger diameter, for example. In another aspect, the invention involves method whereby a third interfacial phase at a metallic glass alloy/refractory metal interface is effectively controlled to produce composites with advantageous properties.

Abstract: The invention encompasses a method of forming a metallic coating. A metallic glass coating is formed over a metallic substrate. After formation of the coating, at least a portion of the metallic glass can be converted into a crystalline material having a nanocrystalline grain size. The invention also encompasses metallic coatings comprising metallic glass. Additionally, the invention encompasses metallic coatings comprising crystalline metallic material, with at least some of the crystalline metallic material having a nanocrystalline grain size.

Abstract: The invention encompasses a method of forming a metallic coating. A metallic glass coating is formed over a metallic substrate. After formation of the coating, at least a portion of the metallic glass can be converted into a crystalline material having a nanocrystalline grain size. The invention also encompasses metallic coatings comprising metallic glass. Additionally, the invention encompasses metallic coatings comprising crystalline metallic material, with at least some of the crystalline metallic material having a nanocrystalline grain size.

Abstract: A nanometer-sized porous metallic glass and a method for manufacturing the same are provided. The porous metallic glass includes Ti (titanium) at 50.0 at % to 70.0 at %, Y (yttrium) at 0.5 at % to 10.0 at %, Al (aluminum) at 10.0 at % to 30.0 at %, Co (cobalt) at 10. at % to 30.0 at %, and impurities. Ti+Y+Al+Co+the impurities=100.0 at %.

Abstract: A composite metal object comprises ductile crystalline metal particles in an amorphous metal matrix. An alloy is heated above its liquidus temperature. Upon cooling from the high temperature melt, the alloy chemically partitions, forming dendrites in the melt. Upon cooling the remaining liquid below the glass transition temperature it freezes to the amorphous state, producing a two-phase microstructure containing crystalline particles in an amorphous metal matrix. The ductile metal particles have a size in the range of from 0.1 to 15 micrometers and spacing in the range of from 0.1 to 20 micrometers. Preferably, the particle size is in the range of from 0.5 to 8 micrometers and spacing is in the range of from 1 to 10 micrometers. The volume proportion of particles is in the range of from 5 to 50% and preferably 15 to 35%. Differential cooling can produce oriented dendrites of ductile metal phase in an amorphous matrix.

Abstract: An amorphous alloy having a composition consisting essentially of about 45 to about 65 atomic % Zr and/or Hf, about 4 to about 7.5 atomic % Ti and/or Nb, about 5 to about 15 atomic % Al and/or Zn, and the balance comprising a metal selected from the group consisting of Cu, Co, Ni, up to about 10 atomic % Fe, and Y intentionally present in the alloy composition in an amount not exceeding about 0.5 atomic %, such as about 0.2 to about 0.4 atomic % Y, with an alloy bulk oxygen concentration of at least about 1000 ppm on atomic basis.

Abstract: The present invention relates to a Cu-based amorphous alloy composition having a chemical composition represented by the following general formula, by atomic %: Cu100-a-b-c-dZraAlb(M1)c(M2)d, where a, b, c and d satisfy the formulas of 36?a?49, 1?b?10, 0?c?10, and 0?d?5, respectively, and c and d are not zero at the same time, and M1, the 4th element added to a ternary alloy of Cu—Zr—Al, is one metal element selected from the group consisting of Nb, Ti, Be and Ag, and M2, the 5th element added to the ternary alloy of the Cu—Zr—Al, is one amphoteric element or non-metal element selected from the group consisting of Sn and Si.

Abstract: Metallic glasses of superior mechanical and magnetic properties are manufactured by annealing the glasses under the influence of an electric current to convert the glass to a composite that includes crystallites, preferably nanocrystallites, dispersed through an amorphous matrix.

Abstract: A method of producing metal fibers including melting a mixture of at least a fiber metal and a matrix metal, cooling the mixture to form a bulk matrix comprising at least a fiber phase and a matrix phase and removing at least a substantial portion of the matrix phase from the fiber phase. Additionally, the method may include deforming the bulk matrix. In certain embodiments, the fiber metal may be at least one of niobium, a niobium alloy, tantalum and a tantalum alloy and the matrix metal may be at least one of copper and a copper alloy. The substantial portion of the matrix phase may be removed, in certain embodiments, by dissolving of the matrix phase in a suitable mineral acid, such as, but not limited to, nitric acid, sulfuric acid, hydrochloric acid and phosphoric acid.

Abstract: Changing characteristics of relationships between components of a bulk metallic glass to stabilize one phase relative to another. A specific Zr58.47Nb2.76Cu15.4Ni12.6Al10.37 alloy is disclosed.

Abstract: The invention includes a method of producing a hard metallic material by forming a mixture containing at least 55% iron and at least one of B, C, Si and P. The mixture is formed into an alloy and cooled to form a metallic material having a hardness of greater than about 9.2 GPa. The invention includes a method of forming a wire by combining a metal strip and a powder. The strip and the powder are rolled to form a wire containing at least 55% iron and from 2–7 additional elements including at lease one of C, Si and B. The invention also includes a method of forming a hardened surface on a substrate by processing a solid mass to form a power, applying the powder to a surface to form a layer containing metallic glass, and converting the glass to a crystalline material having a nanocrystalline grain size.

Abstract: A method and apparatus are invented for producing an amorphous metal, which can readily realize amorphous metal fine particles of sub-micron order to 100 micron order including fine particles of several micrometer of a material from which an amorphous metal cannot be realized by conventional amorphous metal producing method and apparatus, with a high yield and an excellent extraction rate. A molten metal (1) is supplied into a liquid coolant (4), boiling due to spontaneous-bubble nucleation is generated, the molten metal (1) is rapidly cooled while forming fine particles thereof by utilizing a pressure wave generated by this boiling, thereby obtaining an amorphous metal.

Abstract: Improved bulk-solidifying amorphous alloy compositions and methods of making and casting such compositions are provided. The improved bulk-solidifying amorphous alloys are preferably subjected to a superheating treatment and subsequently are cast into articles with high elastic limit. The invention allows use of lower purity raw-materials, and as such effectively reduces the overall cost of the final articles. Furthermore, the invention provides for the casting of new alloys into shapes at lower cooling rates then is possible with the conventional bulk-solidifying amorphous alloys.

Abstract: In accordance with a preferred embodiment of the invention, an alloy or other composite material is provided formed of a bulk metallic glass matrix with a microstructure of crystalline metal particles. The alloy preferably has a composition of (XaNibCuc)100?d?cYdAlc, wherein the sum of a, b and c equals 100, wherein 40?a?80, 0?b?35, 0?c?40, 4?d?30, and 0?e?20, and wherein preferably X is composed of an early transition metal and preferably Y is composed of a refractory body-centered cubic early transition metal. A preferred embodiment of the invention also provides a method of producing an alloy composed of two or more phases at ambient temperature. The method includes the steps of providing a metastable crystalline phase composed of at least two elements, heating the metastable crystalline phase together with at least one additional element to form a liquid, casting the liquid, and cooling the liquid to form the alloy.

Abstract: An amorphous alloy having a composition represented by the formula (Zr,Hf)a(Al,Zn)bTie,Nbf,TagYh(CuxFey(Ni,Co)z)d wherein a ranges from 45 to 65 atomic %, b ranges from 5 to 15 atomic %, e and f each ranges from 0 to 4.5 atomic %, g ranges from greater than 0 to 2 atomic %, h ranges from 0 to 0.5 atomic %, and the balance is d and incidental impurities and wherein e+f+g ranges from 3.5 to 7.5 atomic %, d times y is less than 10 atomic %, and x/z ranges from 0.5 to 2.

Abstract: A method for forming molded articles of bulk-solidifying amorphous alloys around the glass transition range, which preserves the high elastic limit of the bulk solidifying amorphous alloy upon the completion of molding process is provided. The method comprising providing a feedstock of bulk solidifying amorphous alloy, then molding the amorphous alloy feedstock around the glass transition range to form a molded article according to the current invention which retains an elastic limit of at least 1.2%.

Abstract: The method of the present invention incorporates an amorphous metal powder coated with a ductile crystalline metal or alloy. The coated powder is consolidated to form a dense compact of isolated or continuous amorphous metal particles within a continuous ductile metal network. This provides a material in bulk product form exhibiting improved fracture properties including ductility and fracture toughness.

Abstract: An alloy design approach to modify and improve existing iron based glasses. The modification is related to increasing the stability of the glass, which results in increased crystallization temperature, and increasing the reduced crystallization temperature (Tcrystalization/Tmelting), which leads to a reduced critical cooling rate for metallic glass formation. The modification to the iron alloys includes the additional of lanthanide elements, including gadolinium.

Abstract: The present invention is directed to a method of joining an amorphous material to a non-amorphous material including, forming a cast mechanical joint between the bulk solidifying amorphous alloy and the non-amorphous material.

Abstract: Methods of fabricating a free standing thin film of shape memory alloy material, and products made by the methods. A sacrificial layer of a metallic material is deposited onto the surface of a substrate. Then an amorphous shape memory alloy is sputter deposited onto the outer surface of the sacrificial layer. The sacrificial layer is etched away, leaving the thin film free standing, that is separated from the substrate. The thin film is annealed by heating into a crystalline state, with the annealing step carried out either after the film has been separated from the substrate, or while remaining attached to it.

Abstract: A metal frame for electronic hardware and a method of manufacturing such a frame wherein at least a portion of the frame is made of bulk-solidifying amorphous alloys or bulk-solidifying amorphous alloy-composites is provided. The metal frames of the invention are preferably made of bulk-forming amorphous alloys or bulk-forming amorphous alloy-composites having an elastic limit for the metal frame of at least about 1.5%, and preferably greater than about 2.0%, a &Dgr;Tsc of more than 30° C., and at least one of the following properties: a hardness value of about 4 GPA or more, and preferably 5.5 GPA or more; a yield strength of about 2 GPa or more; a fracture toughness of about 10 ksi-sqrt(in) (sqrt:squre root) or more, and preferably 20 ksi sqrt(in) or more; and a density of at least 4.5 g/cc or more.

Abstract: The invention encompasses a method of forming a metallic coating. A metallic glass coating is formed over a metallic substrate. After formation of the coating, at least a portion of the metallic glass can be converted into a crystalline material having a nanocrystalline grain size. The invention also encompasses metallic coatings comprising metallic glass. Additionally, the invention encompasses metallic coatings comprising crystalline metallic material, with at least some of the crystalline metallic material having a nanocrystalline grain size.

Abstract: An amorphous alloy ribbon free from embrittlement and crystallization and having excellent surface conditions and shape in edge portions is produced by (a) preparing an alloy melt having a composition comprising 13 atomic % or less of B and 15 atomic % or less of at least one selected from the group consisting of transition elements of Groups 4A, 5A and 6A, the balance being substantially Fe; (b) ejecting the alloy melt at a temperature from the melting point of the alloy +50° C. to the melting point of the alloy +250° C. through a nozzle onto the cooling roll rotating at a peripheral speed of 35 m/second or less, a distance between a tip end of the nozzle and the cooling roll being 200 &mgr;m or less; (c) starting to supply a gas based on CO2 to the alloy melt after the surface temperature of the cooling roll has become substantially constant; and (d) grinding the cooling roll while supplying the gas based on CO2.

Abstract: An amorphous alloy having a composition represented by the formula (Zr,Hf)a(Al,Zn)bTie,Nbf,TagYh(CuxFey(Ni,Co)z)d wherein a ranges from 45 to 65 atomic %, b ranges from 5 to 15 atomic %, e and f each ranges from 0 to 4.5 atomic %, g ranges from greater than 0 to 2 atomic %, h ranges from 0 to 0.5 atomic %, and the balance is d and incidental impurities and wherein e+f+g ranges from 3.5 to 7.5 atomic %, d times y is less than 10 atomic %, and x/z ranges from 0.5 to 2.

Abstract: Aluminum alloys having improved strength characteristics at elevated temperatures (300° C.) are manufactured by combining selected transition metals (Ni, Co, Ti, Fe, Y, Sc) and selected rare earth materials (Er, Tm, Tb, Lu) in amounts of about 2 to 12% and 2 to 15% atomic percent respectively in an amorphous, glassy state and subsequently devitrifying the amorphous material to form a crystalline mix of fcc and L12 phase material. Devitrification from the amorphous state may be effected by various means including thermal and thermo mechanical processes.

Abstract: A composite metal object comprises ductile crystalline metal particles in an amorphous metal matrix. An alloy is heated above its liquidus temperature. Upon cooling from the high temperature melt, the alloy chemically partitions, forming dendrites in the melt. Upon cooling the remaining liquid below the glass transition temperature it freezes to the amorphous state, producing a two-phase microstructure containing crystalline particles in an amorphous metal matrix. The ductile metal particles have a size in the range of from 0.1 to 15 micrometers and spacing in the range of from 0.1 to 20 micrometers. Preferably, the particle size is in the range of from 0.5 to 8 micrometers and spacing is in the range of from 1 to 10 micrometers. The volume proportion of particles is in the range of from 5 to 50% and preferably 15 to 35%. Differential cooling can produce oriented dendrites of ductile metal phase in an amorphous matrix.

Abstract: Changing characteristics of relationships between components of a bulk metallic glass to stabilize one phase relative to another. A specific Zr58.47Nb2.76Cu15.4Ni12.6Al10.37 alloy is disclosed.

Abstract: A foamed structure of bulk solidifying amorphous alloy with improved impact resistance, with high stiffness to weight ratio, and/or with high resistance to fatigue and crack propagation, and a method for forming such foamed structures are provided.

Abstract: An alloy is described that is capable of forming a metallic glass at moderate cooling rates and exhibits large plastic flow at ambient temperature. Preferably, the alloy has a composition of (Zr, Hf)a TabTicCudNieAlf, where the composition ranges (in atomic percent) are 45≦a≦70, 3≦b≦7.5, 0≦c≦4, 3≦b+c≦10, 10≦d≦30, 0≦e≦20, 10≦d+e≦35, and 5≦f≦15. The alloy may be cast into a bulk solid with disordered atomic-scale structure, i.e., a metallic glass, by a variety of techniques including copper mold die casting and planar flow casting. The as-cast amorphous solid has good ductility while retaining all of the characteristic features of known metallic glasses, including a distinct glass transition, a supercooled liquid region, and an absence of long-range atomic order. The alloy may be used to form a composite structure including quasi-crystals embedded in an amorphous matrix.

Abstract: A Zr-based bulk metallic glass formed using low purity materials at a low vacuum with a small amount of yttrium addition is provided. A method of improving the glass forming ability, crystallization and melting process without reducing the mechanical and elastic properties, such as hardness and Young's Modulus, of Zr-based alloys by yttrium addition, is also provided.

Abstract: A new metallic glass is formed by adding special additives to a metallic glass matrix; the additives having ductile properties to form as dendrites in the metallic glass. The additives distribute the shear lines in the metallic glass, allowing it to plastically deform more than previous materials.