Abstract: Embossing of metallic glass supercooled liquids into templates is emerging as a precision net-shaping and surface patterning technique for metals. Here, the effect of thickness of metallic glass on template-based embossing is disclosed. The results show that the existing embossing theory developed for thick samples fails to describe the process when the thickness of metallic glass becomes comparable to the template cavity diameter. Increased flow resistance at the cavity entrance results in viscous buckling of supercooled liquid instead of filling. A new phenomenological equation is proposed to describe the thickness dependent filling of template cavities. The buckling phenomenon is analyzed based on the folding model of multilayer viscous media. Controlled buckling can be harnessed in fabrication of metal microtubes, which are desirable for many emerging applications.

Abstract: A method of processing BMGs in a non-ideal environment (such as air) to create a uniform and smooth surface is provided. By utilizing the contact-line movement and an engineered flow pattern during TPF the method is able to create complex BMG parts that exhibit uniform smooth appearance or even can be atomically smooth. In addition, to mending surface imperfections, this method also eliminates void formation inside the material, allows for the creation of precise patterns of homogeneous appearance, and forms improved mechanical locks between different materials and a BMG.

Abstract: A method of processing BMGs in a non-ideal environment (such as air) to create a uniform and smooth surface is provided. By utilizing the contact-line movement and an engineered flow pattern during TPF the method is able to create complex BMG parts that exhibit uniform smooth appearance or even can be atomically smooth. In addition, to mending surface imperfections, this method also eliminates void formation inside the material, allows for the creation of precise patterns of homogeneous appearance, and forms improved mechanical locks between different materials and a BMG.