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: Radiation shielding structures comprising bulk-solidifying amorphous alloys and methods of making radiation shielding structures and components in near-to-net shaped forms are provided.

Abstract: Various embodiments provide apparatus and methods for melting materials and for containing the molten materials within melt zone during melting. Exemplary apparatus may include a vessel configured to receive a material for melting therein; a load induction coil positioned adjacent to the vessel to melt the material therein; and a containment induction coil positioned in line with the load induction coil. The material in the vessel can be heated by operating the load induction coil at a first RF frequency to form a molten material. The containment induction coil can be operated at a second RF frequency to contain the molten material within the load induction coil. Once the desired temperature is achieved and maintained for the molten material, operation of the containment induction coil can be stopped and the molten material can be ejected from the vessel into a mold through an ejection path.

Abstract: Embodiments relates to a hook side fastener having hooks and a loop side fastener having loops. The hooks and/or loops are made of bulk solidifying amorphous metal alloy. Other embodiments relate to methods of making and using the hook side and loop side fasteners.

Abstract: Embodiments herein relate to a method of making roll formed objects of a bulk solidifying amorphous alloy comprising a metal alloy, and articles thereof. The roll forming includes forming a portion of the bulk solidifying amorphous alloy at a temperature greater than a glass transition temperature (Tg) of the metal alloy. The roll forming is done such that a time-temperature profile of the portion during the roll forming does not traverse through a region bounding a crystalline region of the metal alloy in a time-temperature-transformation (TTT) diagram of the metal alloy.

Abstract: Described herein is a method of producing an alloy. The method includes pouring a stream of molten mixture of component elements of the alloy, separating the stream into discrete pieces, solidifying the discrete pieces by cooling before the discrete pieces contact any liquid or solid. Also described herein is another method of producing an alloy. This method includes pouring and solidifying a stream of molten mixture of component elements of the alloy into a rod or pulling a rod from a molten mixture of component elements of the alloy, before the rod contacts any liquid or solid, separating the rod into discrete pieces. An apparatus suitable for carrying out the methods above can include a container from which the molten stream is poured or the solid rod extends, one or more coil, conductive plates, a laser source, or an electron beam source arranged around the molten stream or the solid rod and configured to separate the molten stream or the solid rod into discrete pieces.

Abstract: Disclosed are systems and methods for mechanically reducing an amount of the skull material in a finished, molded part formed from amorphous alloy using an injection molding system. Skull material of molten amorphous alloy can be captured in a trap before molding such material. A cavity can be provided in the injection molding system to trap the skull material. For example, the cavity can be provided in the mold, the tip of the plunger rod, or in the transfer sleeve. Alternatively, mixing of molten amorphous alloy can be induced so that skull material is reduced before molding. A plunger and/or its tip can be used to induce mixing (e.g., systematic movement of plunger rod, or a shape of its tip). By minimizing the amount of skull material in the finished, molded part, the quality of the part is increased.

Abstract: An induction shield is configured to substantially reduce emissions emitted from an induction heat source (e.g., coil) during use. The shield is positioned adjacent to a vessel (e.g., in an injection system) having a melting portion configured to receive meltable material to be melted therein and an induction heat source positioned adjacent the vessel configured to melt the meltable material received in the melting portion of the vessel. The shield may include a tube configuration configured to flow liquid therein to absorb heat emitted from the heat source. The tube configuration can comprise a single tube or multiple tubes. The shield can be positioned adjacent the induction source in a helical manner, for example, or at ends of the vessel. The shield can be used during melting of amorphous alloy and for forming a part.

Abstract: Various embodiments provide apparatus and methods for melting materials and for containing the molten materials within melt zone during melting. Exemplary apparatus may include a vessel configured to receive a material for melting therein; a load induction coil positioned adjacent to the vessel to melt the material therein; and a containment induction coil positioned in line with the load induction coil. The material in the vessel can be heated by operating the load induction coil at a first RF frequency to form a molten material. The containment induction coil can be operated at a second RF frequency to contain the molten material within the load induction coil. Once the desired temperature is achieved and maintained for the molten material, operation of the containment induction coil can be stopped and the molten material can be ejected from the vessel into a mold through an ejection path.

Abstract: Exemplary embodiments described herein relate to methods and apparatus for forming a coating layer at least partially on surface of a BMG article formed of bulk solidifying amorphous alloys. In embodiments, the coating layer may be formed in situ during formation of a BMG article and/or post formation of a BMG article. The coating layer may provide the BMG article with surface hardness, wear resistance, surface activity, corrosion resistance, etc.

Abstract: Various embodiments provide methods and apparatus for forming bulk metallic glass (BMG) articles using a mold having a stationary mold part and a movable mold part paired to form a mold cavity. A molten material can be injected to fill the mold cavity. The molten material can then be cooled into a BMG article at a desired cooling rate. While injecting and/or cooling the molten material, the movement of the movable mold part can be controlled, such that a thermal contact between the molten material and the mold can be maintained. BMG articles can be formed without forming an underfilled part. Additional structural features can be imparted in the BMG article during formation. At least a portion of the formed BMG article can have an aspect ratio (first dimension/second dimension) of at least 10 or less than 0.1.

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: Vessels used for melting material to be injection molded to form a part are described. One vessel has a body formed from a plurality of elongate segments configured to be electrically isolated from each other and with a melting portion for melting meltable material therein. Material can be provided between adjacent segments. An induction coil can be used to melt the material in the body. Other vessels have a body with an embedded induction coil therein. The embedded coil can be configured to surround the melting portion, or can be positioned below and/or adjacent the melting portion, so that meltable material is melted. The vessels can be used to melt amorphous alloys, for example.

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: 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: 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: 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: 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: 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: Exemplary embodiments described herein related 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.