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: 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: A golf club is made of a club shaft and a club head. Either the club shaft or the club head is made at least in part of a bulk-solidifying amorphous metal. A preferred bulk-solidifying amorphous metal has a composition, in atomic percent, of from about 45 to about 67 percent total of zirconium plus titanium, from about 10 to about 35 percent beryllium, and from about 10 to about 38 percent total of copper plus nickel, plus incidental impurities, the total of the percentages being 100 atomic percent. The weights of the various club heads of a set, which have different volumes, may be established by varying the compositions and thence the densities of the bulk-solidifying amorphous alloys.

Abstract: A process and apparatus for thermoplastic casting of a suitable glass forming alloy is provided. The method and apparatus comprising thermoplastically casting the alloy in either a continuous or batch process by maintaining the alloy at a temperature in a thermoplastic zone, which is below a temperature, Tnose, (where, the resistance to crystallization is minimum) and above the glass transition temperature, Tg, during the shaping or moulding step, followed by a quenching step where the item is cooled to the ambient temperature. A product formed according to the thermoplastic casting process is also provided.

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: 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: 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 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: Sharp-edged cutting tools and a method of manufacturing sharp-edged cutting tools wherein at least a portion of the sharp-edged cutting tool is formed from a bulk amorphous alloy material are provided.

Abstract: Gliding board devices and methods of making gliding board devices wherein at least a portion of the device is formed of a bulk amorphous alloy material are provided. The gliding board device including an upper reinforcing element that covers at least the upper surface of the device; a lower reinforcing element; a sliding element; a pair of running edges; and a core of filler material disposed between the upper and lower elements, wherein at least one of the upper reinforcing element, lower reinforcing element and pair of running edges are formed from an amorphous alloy.

Abstract: A shaped-charge projectile includes a container in the form of a hollow shell elongated parallel to a projectile axis, with the container having a front end and a back end. A shaped-charge liner is within the container and adjacent to the front end of the container. The shaped-charge liner is a composite material of fibers or particles of a solid reinforcement dispersed in a solid amorphous matrix. An explosive charge is positioned between the shaped-charge liner and the back end of the container. The shaped-charge liner is preferably prepared by infiltration or casting, and assembled with the other elements to make the shaped-charge projectile.

Abstract: The surface features of an article are replicated by preparing a master model having a preselected surface feature thereon which is to be replicated, and replicating the preselected surface feature of the master model. The replication is accomplished by providing a piece of a bulk-solidifying amorphous metallic alloy, contacting the piece of the bulk-solidifying amorphous metallic alloy to the surface of the master model at an elevated replication temperature to transfer a negative copy of the preselected surface feature of the master model to the piece, and separating the piece having the negative copy of the preselected surface feature from the master model.

Abstract: A metallic article is fabricated by providing a die and a piece of a bulk-solidifying amorphous metallic alloy having a glass transition temperature. The bulk-solidifying amorphous metallic alloy is heated to a forming temperature of from about 0.75 T.sub.g to about 1.2 T.sub.g and forced into the die cavity at the forming temperature under an external pressure of from about 260 to about 40,000 pounds per square inch, thereby deforming the piece of the bulk-solidifying amorphous metallic alloy to a formed shape that fills the die cavity. Preferably, a pressure is applied to the piece of the bulk-solidifying amorphous metallic alloy as it is heated, and the heating rate is at least about 0.1.degree. C. per second. The die may be a male die or a female die. When the die has a re-entrant comer therein, the formed shape of the bulk-solidifying amorphous metallic alloy is mechanically locked to the die.

Abstract: A reinforcement-containing metal-matrix composite material is formed by dispersing pieces of reinforcement material throughout a melt of a bulk-solidifying amorphous metal and solidifying the mixture at a sufficiently high rate that the solid metal matrix is amorphous. Dispersing is typically accomplished either by melting the metal and mixing the pieces of reinforcement material into the melt, or by providing a mass of pieces of the reinforcement material and infiltration of the molten amorphous metal into the mass. The metal preferably has a composition of about that of a eutectic composition, and most preferably has a composition, in atomic percent, of from about 45 to about 67 percent total of zirconium plus titanium, from about 10 to about 35 percent beryllium, and from about 10 to about 38 percent total of copper plus nickel.

Abstract: A casting charge of a bulk-solidifying amorphous alloy is cast into a mold from a temperature greater than its crystallized melting temperature, and permitted to solidify to form an article. The oxygen content of the casting charge is limited to an operable level, as excessively high oxygen contents produce premature crystallization during the casting operation. During melting, the casting charge is preferably heated to a temperature above a threshold temperature to eliminate heterogeneous crystallization nucleation sites within the casting charge. The casting charge may be cast from above the threshold temperature, or it may be cooled to the casting temperature of more than the crystallized melting point but not more than the threshold temperature, optionally held at this temperature for a period of time, and thereafter cast.

Abstract: A torsionally reacting spring, such as a helical spring, a torsion bar, or a torsion tube, requires the ability to torsionally deform elastically during service and return to its original, undeformed shape. The torsionally reacting spring is made of a bulk-deforming amorphous alloy which may be cooled from the melt at a cooling rate of less than about 500.degree. C. per second, yet retain an amorphous structure. A preferred bulk-solidifying amorphous alloy has a composition, in atomic percent, of from about 45 to about 67 percent total of zirconium plus titanium, from about 10 to about 35 percent beryllium, and from about 10 to about 38 percent total of copper plus nickel, plus incidental impurities, the total of the percentages being 100 atomic percent.

Abstract: Solid die-cast articles are prepared from a charge of a bulk-solidifying amorphous alloy. The charge is heated to an injection temperature and injected into a die-casting mold. The charge is cooled at a rate, about 500.degree. C. per second or less, such that its amorphous structure is retained in the solidified article.

Abstract: At least quaternary alloys form metallic glass upon cooling below the glass transition temperature at a rate less than 10.sup.3 K/s. Such alloys comprise titanium from 19 to 41 atomic percent, an early transition metal (ETM) from 4 to 21 atomic percent and copper plus a late transition metal (LTM) from 49 to 64 atomic percent. The ETM comprises zirconium and/or hafnium. The LTM comprises cobalt and/or nickel. The composition is further constrained such that the product of the copper plus LTM times the atomic proportion of LTM relative to the copper is from 2 to 14. The atomic percentage of ETM is less than 10 when the atomic percentage of titanium is as high as 41, and may be as large as 21 when the atomic percentage of titanium is as low as 24. Furthermore, when the total of copper and LTM are low, the amount of LTM present must be further limited. Another group of glass forming alloys has the formula(ETM.sub.1-x Ti.sub.x).sub.a Cu.sub.b (Ni.sub.1-y Co.sub.y).sub.cwherein x is from 0.1 to 0.3, y.cndot.

Abstract: A diamond-containing metal-matrix composite material is formed by dispersing pieces of diamond throughout a melt of a bulk-solidifying amorphous metal and solidifying the mixture. The mixture may then be remelted and resolidified at a rate sufficiently high that the metal matrix retains an amorphous structure upon cooling. The metal preferably has a composition of about that of a eutectic composition, and most preferably has a composition, in atomic percent, of from about 45 to about 67 percent total of zirconium plus titanium, from about 10 to about 35 percent beryllium, and from about 10 to about 98 percent total of copper plus nickel. The diamond is preferably low-grade or artificial diamond.

Abstract: A reinforcement-containing metal-matrix composite material is formed by dispersing pieces of reinforcement material throughout a melt of a bulk-solidifying amorphous metal and solidifying the mixture at a sufficiently high rate that the solid metal matrix is amorphous. Dispersing is typically accomplished either by melting the metal and mixing the pieces of reinforcement material into the melt, or by providing a mass of pieces of the reinforcement material and infiltration of the molten amorphous metal into the mass. The metal preferably has a composition of about that of a eutectic composition, and most preferably has a composition, in atomic percent, of from about 45 to about 67 percent total of zirconium plus titanium, from about 10 to about 35 percent beryllium, and from about 10 to about 38 percent total of copper plus nickel.