Abstract: Described herein is a plunger of an injection molding machine, comprising a plunger body; a plunger tip that is a separate element from the plunger body and comprises an end surface configured to directly contact a molten material used in injection molding in the injection molding machine; wherein thermal conductance across the end surface of the plunger tip may be adjustable by moving the plunger tip relative to the plunger body such that temperature of the plunger tip may be adjusted during injection molding. When this plunger is used to injection molding of a BMG, it allows reduction of formation of crystalline phases near the plunger tip and allows replacement of the plunger tip without replacement of the plunger body.

Abstract: Disclosed herein is a device comprising: vacuum chamber; a stage configured to receive BMG in a molten state or a BMG feedstock, configured to spin, and located in the vacuum chamber; a heater configured to melt the BMG feedstock or to keep BMG in a molten state molten; wherein the stage comprises one or more conduits therein and the conduits are configured to accommodate a cooling fluid. Also disclosed herein is a method of forming a solid BMG sheet, the method comprising: disposing BMG in a molten state onto a stage; spreading the BMG in a molten state into a sheet of BMG in a molten state by spinning the stage; cooling the sheet of BMG in a molten state to form a solid BMG sheet.

Abstract: Various embodiments provide apparatus and methods for melting and introducing alloy feedstock for molding by using a hollow branch having a constraint mechanism therein. In one embodiment, a hollow branch can extend upward from a cold chamber that is substantially horizontally configured. The hollow branch including a constraint mechanism can be capable of containing an alloy feedstock for melting into the molten alloy in the hollow branch and introducing the molten alloy to the cold chamber for molding.

Abstract: Bulk solidifying amorphous alloys exhibiting improved processing and mechanical properties and methods of forming these alloys are provided. The bulk solidifying amorphous alloys are composed to have high Poisson's ratio values. Exemplary Pt-based bulk solidifying amorphous alloys having such high Poisson's ratio values are also described. The Pt-based alloys are based on Pt—Ni—Co—Cu—P alloys, and the mechanical properties of one exemplary alloy having a composition of substantially Pt57.5Cu14.7Ni5.3P22.5 are also described.

Abstract: Antenna structures made of bulk-solidifying amorphous alloys and methods of making antenna structures from such bulk-solidifying amorphous alloys are described. The bulk-solidifying amorphous alloys providing form and shape durability, excellent resistance to chemical and environmental effects, and low-cost net-shape fabrication for the highly intricate antenna shapes.

Abstract: Various embodiments provide apparatus and methods for melting and introducing alloy feedstock for molding by using a hollow branch having a constraint mechanism therein. In one embodiment, a hollow branch can extend upward from a cold chamber that is substantially horizontally configured. The hollow branch including a constraint mechanism can be capable of containing an alloy feedstock for melting into the molten alloy in the hollow branch and introducing the molten alloy to the cold chamber for molding.

Abstract: Various embodiments provide apparatus and methods for injection molding. In one embodiment, a constraining plunger may be configured in-line with an injection plunger to transfer a molten material from a melt zone and into a mold. The constraining and injection plungers are configured to constrain the molten material there-between while moving. The constrained molten material can be controlled to have an optimum surface area to volume ratio to provide minimized heat loss during the injection molding process. The system can be configured in a longitudinal direction (e.g., horizontally) for movement between the melt zone and mold along a longitudinal axis. A molded bulk amorphous object can be ejected from the mold.

Abstract: One embodiment provides an article, comprising: an inner container having a cavity, the inner container comprising a ceramic; and an outer container, the outer container comprising a susceptor; wherein at least a portion of an outer surface of the inner container is in contact with an inner surface of the outer container, and wherein the inner container is removable from the mold. Methods of melting using the present article are also provided.

Abstract: The embodiments described herein relate to methods and apparatus for counter-gravity formation of BMG-containing hollow parts. In one embodiment, the BMG-containing hollow parts may be formed by first feeding a molten metal alloy in a counter-gravity direction into a mold cavity to deposit the molten metal alloy on a surface of the mold cavity and then solidifying the deposited molten metal alloy.

Abstract: Metallic dental prostheses made of bulk-solidifying amorphous alloys wherein the dental prosthesis has an elastic strain limit of around 1.2% or more and methods of making such metallic dental prostheses are provided.

Abstract: The embodiments described herein relate to methods and apparatus for counter-gravity formation of BMG-containing hollow parts. In one embodiment, the BMG-containing hollow parts may be formed by first feeding a molten metal alloy in a counter-gravity direction into a mold cavity to deposit the molten metal alloy on a surface of the mold cavity and then solidifying the deposited molten metal alloy.

Abstract: Metallic dental prostheses made of bulk-solidifying amorphous alloys wherein the dental prosthesis has an elastic strain limit of around 1.2% or more and methods of making such metallic dental prostheses are provided.

Abstract: Described herein is a method of selectively depositing molten bulk metallic glass (BMG). In one embodiment, a continuous stream or discrete droplets of molten BMG is deposited to selected positions. The deposition can be repeated as needed layer by layer. One or more layers of non-BMG can be used as needed.

Abstract: Described herein is a feedstock including a core comprising BMG and a sheath attached the core. The sheath has a different physical property, a different chemical property or both from the core. Alternatively, the feedstock can include a sheath that encloses one or more core comprising BMG. The feedstock can be manufactured by attaching the sheath to the core, shot peening the core, etching the core, ion implanting the core, or applying a coating to the core, etc. The feedstock can be used to make a part by injection molding. The sheath can be used to adjust the composition of the core to reach the composition of the part.

Abstract: Described herein are methods of constructing a part using BMG layer by layer. In one embodiment, a layer of BMG powder is deposited to selected positions and then fused to a layer below by suitable methods such as laser heating or electron beam heating. The deposition and fusing are then repeated as need to construct the part layer by layer. One or more layers of non-BMG can be used as needed. In one embodiment, layers of BMG can be cut from one or more sheets of BMG to desired shapes, stacked and fused to form the part.

Abstract: Described herein is a feedstock comprising BMG. The feedstock has a surface with an average roughness of at least 200 microns. Also described herein is a feedstock comprising BMG. The feedstock, when supported on a support during a melting process of the feedstock, has a contact area between the feedstock and the support up to 50% of a total area of the support. These feedstocks can be made by molding ingots of BMG into a mole with surface patterns, enclosing one or more cores into a sheath with a roughened surface, chemical etching, laser ablating, machining, grinding, sandblasting, or shot peening. The feedstocks can be used as starting materials in an injection molding process.

Abstract: Described herein is a method of combining discrete pieces of BMG in to a BMG feedstock that has at least one dimension greater than a critical dimension of the BMG, by methods such as thermoplastic forming, pressing, extruding, folding or forging. Other embodiments relate to a bulk metallic glass (BMG) component or feedstock having discrete pieces of a BMG, wherein the BMG component or feedstock has at least one dimension greater than a critical dimension of the BMG.

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: A process and apparatus for continuous casting of amorphous alloy sheets having large sheet thickness using bulk solidifying amorphous alloys are provided. Thick continuous amorphous alloy sheets made of bulk solidifying amorphous alloys are also provided.

Abstract: Methods and apparatuses for the continuous casting of solid foam structures with varying bubble density from bulk solidifying amorphous alloys are provided. Continuously cast solid foam structures having bubble densities in the range of from 50 percent up to 95% by volume are also provided.