Abstract: Described herein is a device comprising a crucible, a movable base and a heater; wherein the heater is configured to melt BMG to form molten BMG feedstock in the crucible; wherein the movable base configured to slide along a length of the crucible; wherein the movable base and the crucible are configured to hold the molten BMG feedstock.

Abstract: Described herein is a method of melting a bulk metallic glass (BMG) feedstock, comprising: heating at least a portion of the BMG feedstock to temperatures slightly below a solidus temperature of the BMG, wherein the portion remains a solid at the temperatures slightly below the solidus temperature and wherein a temperature distribution of the portion is essentially uniform; heating the portion of the BMG feedstock to temperatures above a liquidus point.

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: Various embodiments provide methods and apparatus for active cooling regulation of a melting process. In one embodiment, a meltable material can be melted in a vessel that includes cooling channel(s) configured therein. A contact temperature TContact of the vessel at an interface with the melt can be measured and compared with a skull forming temperature TSkull and a wetting temperature TWetting of the melt on the vessel. A cooling rate can be regulated to regulate TContact to be TSkull<TContact<TWetting. In another embodiment, TContact can be regulated in a value close or equal to a wetting threshold temperature TTh-I, wherein TTH-I=TWetting—a temperature safety margin for TWetting. In yet another embodiment, TContact can be regulated such that TTh-II?TContact?TTh-I, wherein TTh-II=TSkull plus a temperature safety margin for TSkull.

Abstract: Disclosed is a vessel for melting and casting meltable materials. The vessel may be a surface temperature regulated vessel for providing a substantially non-wetting interface with the molten materials. In one embodiment, the vessel may include one or more temperature regulating channels configured to flow a fluid therein for regulating a surface temperature of the vessel such that molten materials are substantially non-wetting at the interface with the vessel. Disclosed also includes systems and methods for melting and casting meltable materials using the vessel.

Abstract: Exemplary embodiments described herein relate to methods and systems for casting metal alloys into articles such as BMG articles. In one embodiment, processes involved for storing, pre-treating, alloying, melting, injecting, molding, etc. can be combined as desired and conducted in different chambers. During these processes, each chamber can be independently, separately controlled to have desired chamber environment, e.g., under vacuum, in an inert gas environment, or open to the surrounding environment. Due to the flexible, independent control of each chamber, the casting cycle time can be reduced and the production throughput can be increased. Contaminations of the molten materials and thus the final products are reduced or eliminated.

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: 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: Disclosed are methods and apparatus for determining an unknown degree of amorphicity in a bulk-solidifying amorphous alloy. A specimen can be prepared from the alloy, irradiated with passive radiation, imaged to provide a thermal image, and the image analyzed to assess the differences in emissivities in the image. The degree of amorphicity can be determined based on the differences in thermal emissivities.

Abstract: Provided in one embodiment is a method of making use of foams as a processing aid or to improve the properties of bulk-solidifying amorphous alloy materials. Other embodiments include the bulk-solidifying amorphous alloy/foam composite materials made in accordance with the methods.

Abstract: Provided in an embodiment is a method for molding, including: providing a molten alloy in a space between a mold cavity and an etchable block shaped to form an undercut on a part formed in the space, cooling the molten alloy to form the part with the undercut, and etching the etchable block. An undercut is a beveled edge caused by an etchant attacking an etchable block laterally and optionally vertically. The formed part can be made of a bulk amorphous alloy. In some cases, the etchable block can also be used to form at least one threaded portion in the part.

Abstract: A composite structure includes a matrix material having an intrinsic strain-to-failure rating in tension and a reinforcing material embedded in the bulk material. The reinforcing material is pre-stressed by a tensile force acting along one direction. The embedded reinforcing material interacts with the matrix material to place the composite structure into a compressive state. The compressive state provides an increased strain-to-failure rating in tension of the composite structure along a direction that is greater than the intrinsic strain-to-failure rating in tension of the matrix material along that direction. At least one of the matrix material and the reinforcing material is a bulk amorphous alloy (BAA). The reinforcing material can be a fiber or wire. In various embodiments, the matrix material may be a bulk amorphous alloy and/or the reinforcing material may be a bulk amorphous alloy.

Abstract: The embodiments described herein relate to BMG articles with high bulk having all dimensions greater than the critical dimension. Exemplary BMG article can include at least one bulk component and/or one or more fixation elements configured on surface of the bulk component or inserted into the bulk component. Other embodiments relate to methods of making the BMG articles by thermo-plastic-formation of BMG alloy materials.

Abstract: Disclosed is a method of controlling the production of a bulk-solidifying amorphous alloy by providing a set point control system, run in conjunction with a continuous smart feedback process control system that continuously monitors the processing conditions during manufacture, and continuously updates the smart feedback control system thereby enabling the control system to learn as the process is running.

Abstract: Disclosed herein are methods of combining at least one bulk-solidifying amorphous alloy and at least one additional metal or alloy of a metal to provide a composite preform. The composite preform then is heated to produce an alloy of the bulk-solidifying amorphous alloy and the at least one additional metal or alloy of the metal.

Abstract: Disclosed are quality control methods used in fabrication processes to make bulk-solidifying amorphous alloy parts. The quality control methods include forming a test plaque together with bulk-solidifying amorphous alloy part where the test plaque is formed on the alloy part at a location having a predetermined likelihood of failure, and testing the plaque to determine the quality of the product.

Abstract: Provided in one embodiment is a method of forming a movable joint or connection between parts that move with respect to one another, wherein at least one part is at least partially enclosed by at least one second part. The method includes positioning an etchable material over an at least one first part, molding or forming an at least one second part over at least the etchable material, and removing the etchable material.

Abstract: Disclosed is a method of coating a substrate with a bulk-solidifying amorphous alloy using a thermal spraying technique to provide a coating that is substantially amorphous. Some embodiments include using a substrate having a thickness greater than the critical casting thickness of the bulk-solidifying amorphous alloy, and using a brazing material to assist in adhering the coating to the surface.

Abstract: Touch sensing systems comprising bulk-solidifying amorphous alloys and methods of making touch sensing arrays and electronic devices containing touch sensitive screens that include arrays containing bulk-solidifying amorphous alloys. The bulk-solidifying amorphous alloy substrates have select areas of crystalline and amorphous alloy providing for discrete areas of conductivity and resistivity.

Abstract: Pressure sensing systems comprising bulk-solidifying amorphous alloys and pressure-sensitive switches containing bulk-solidifying amorphous alloys. The bulk-solidifying amorphous alloys are capable of repeated deformation upon application of pressure, and change their electrical resistivity upon deformation, thereby enabling measurement of the change in resistivity and consequently, measuring the deformation and amount of pressure applied.