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To satisfy thermodynamic and kinetic requirements, Fe-based alloys capable of forming bulk metallic glasses often contain five or more elements. Usually, such compositions are of the type transition-metals/metalloids, with metalloid content around 20 atomic%. Starting from known Fe-based compositions used to make melt-spun glassy ribbons, purifying the master alloy by fluxing with B 2 O 3 and using copper mould casting, a ternary Fe 66 Nb 4 B 30 bulk metallic glass was obtained. To our knowledge this is the first Fe-based fully amorphous bulk metallic glass with just three atomic constituents. The alloy is ferromagnetic with Curie temperature T c ¼ 646 K, glass transition temperature T g ¼ 845 K, crystallization temperature T x ¼ 876 K, liquidus temperature T liq ¼ 1451 K and having a mechanical strength of 4 GPa.

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Bobbin tool friction stir welding (BT-FSW) is characterized by a fully penetrated pin and double-sided shoulder that promote symmetrical solid-state joints. However, control of the processing parameters to obtain defect-free thick lap joints is still difficult and needs more effort. In this study, the BT-FSW process was used to produce 10 mm AA1050-H14 similar lap joints. A newly designed bobbin tool (BT) with three different pin geometries (cylindrical, square, and triangular) and concave shoulders profile was designed, manufactured, and applied to produce the Al alloy lap joints. The experiments were carried out at a constant tool rotation speed of 600 rpm and a wide range of various welding travel speeds of 200, 400, 600, 800, and 1000 mm/min. The generated temperature during the BT-FSW process was recorded and analyzed at the joints’ center line, and at both advancing and retreating sides. Visual inspection, macrostructures, hardness, and tensile properties were investigated. The fracture surfaces after tensile testing were also examined. The results showed that the pin geometry and travel speed are considered the most important controlling parameters in BT-FSW thick lap joints. The square (Sq) pin geometry gives the highest BT-FSW stir zone temperature compared to the other two pins, cylindrical (Cy) and triangular (Tr), whereas the Tr pin gives the lowest stir zone temperature at all applied travel speeds from 200 to 1000 mm/min. Furthermore, the temperature along the lap joints decreased with increasing the welding speed, and the maximum temperature of 380 °C was obtained at the lowest travel speed of 200 mm/min with applying Sq pin geometry. The temperature at the advancing side (AS) was higher than that at the retreating side (RS) by around 20 °C. Defect-free welds were produced using a bobbin tool with Cy and Sq pin geometries at all the travel welding speeds investigated. BT-FSW at a travel speed of 200 mm/min leads to the highest tensile shear properties, in the case of using the Sq pin. The hardness profiles showed a significant effect for both the tool pin geometry and the welding speed, whereas the width of the softened region is reduced dramatically with increasing the welding speed and using the triangular pin.

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