Additive manufacturing of an iron-based bulk metallic glass larger than the critical casting thickness

Mahbooba, Zaynab; Thorsson, Lena; Unosson, Mattias; Skoglund, Peter; West, Harvey; Horn, Timothy; Rock, Christopher; Vogli, E.; Harrysson, Ola L. A.

doi:10.1016/j.apmt.2018.02.011

Cited by 106 publications

(57 citation statements)

References 37 publications

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“…It is reported that heat accumulation or mechanical stress during the laser additive manufacturing procedure probably causes the nano-crystal nucleation [28,34]. We also found some nano-crystals in the SLM specimens by TEM ( Figure 13).…”

Section: Hardness and Micro-compressionsupporting

confidence: 55%

“…The basic idea is to block the propagation of the shear bands during the plastic deformation. The research shows that during the SLM process, BMGs with nano-crystals are formed by thermal recycling or stress [21,28]; however, when the volume fraction of nano-crystal is lower than 20%, the deformation ability decreases with the reduction of volume fraction [29]. This enlightens us to enhance the ductility of BMGs by introducing nano-crystals within the amorphous matrix with a volume fraction under 20% by SLM technology.…”

Section: Introductionmentioning

confidence: 98%

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Additive Manufactured Large Zr-Based Bulk Metallic Glass Composites with Desired Deformation Ability and Corrosion Resistance

et al. 2020

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Zr-based bulk metallic glasses have been attracting tremendous interest of researchers because of their unique combination of mechanical and chemical properties. However, their application is limited as large-scale production is difficult due to the limitation of cooling rate. Recently, additive manufacturing technology has been proposed as a new solution for fabricating bulk metallic glasses without size limitation. In this study, selective laser melting technology was used to prepare Zr60Fe10Cu20Al10 bulk metallic glass. The laser parameters for fabricating full dense amorphous specimens were investigated. The mechanical and corrosion resistance properties of the prepared samples were measured by micro-compression and electrochemical corrosion testing, respectively. Lastly, Zr60Fe10Cu20Al10 bulk metallic glass (BMG) with dispersed nano-crystals was made, and good deformation ability was revealed during micro-compression test. The corrosion resistance decreased a bit due to the crystalline phases. The results provide a promising route for manufacturing large and complex bulk metallic glasses with better mechanical property and acceptable corrosion resistance.

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Section: Hardness and Micro-compressionsupporting

confidence: 55%

Section: Introductionmentioning

confidence: 98%

Additive Manufactured Large Zr-Based Bulk Metallic Glass Composites with Desired Deformation Ability and Corrosion Resistance

et al. 2020

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“…Recent advances in additive manufacturing of amorphous Fe-based materials open up new perspectives to create amorphous composite magnets of various sizes and shapes and with controlled microstructure. [21,22]…”

Section: Resultsmentioning

confidence: 99%

Rigid Exchange Coupling in Rare‐Earth‐Lean Amorphous Hard/Soft Nanocomposites

Rani

Muscas

Stopfel

et al. 2020

Adv Elect Materials

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considerably larger than for a single hard phase, since the strong coercivity H c of the hard phase is combined with the high saturation magnetization M s of the soft phase. [7] With sufficiently strong exchange coupling between the two magnetic phases, the soft phase moments will follow the hard phase during magnetization reversal. Such a rigidly exchange-coupled composite exhibits a magnetic hysteresis loop characteristic of a single ferromagnetic phase, [8] rather than a loop with drops, kinks, or shoulders from two superposed switching processes. [9] For most practical applications, it is also crucial that the Curie temperature T c of the composite material is well above room temperature, and that the overall M s value is large. A model for the interfacial exchangespring coupling between a soft and a hard phase was introduced by Goto et al. [10] According to that model, the two phases can reverse their moments coherently, that is, as a single component, only if the coupling is strong enough to extend from the interface through the entire thickness of the soft phase. Thus, for a given combination of soft and hard materials, rigid coupling is only possible up to a critical thickness of the soft phase. Therefore, strong interphase exchange coupling is usually manifested only for nanostructured materials, [11] and the fabrication method and resulting micro-and nanostructure have strong impact on the final magnetic properties of hard/soft nanocomposites and multilayers. [12,13] In crystalline heterostructures, the exchange coupling is often reduced at the interfaces due to structural transitions, defects, or both. [14-16] Multilayers and composites made using amorphous alloys have the advantage that undesirable effects from, for example, atomic steps at interfaces and other structural defects are avoided simply by the amorphous nature, resulting in smooth and continuous interfaces. [17,18] The alternative, to produce high quality epitaxial heterostructures of hard/soft magnets, is a much more cumbersome route toward smooth interfaces. [19] In addition, the epitaxial growth is limited to specific phases with matching lattice constants and specific magnetic properties. The magnetic properties of many amorphous building blocks can, on the other hand, be tuned almost continuously through their composition. [17,20] The sputter process allows industrial-scale production of amorphous multilayers with smooth interfaces, while recent advances in additive manufacturing of amorphous Febased materials open up new perspectives to create amorphous composite magnets of larger sizes and different shapes. [21,22] Electrification of vehicles and renewable energy is increasing the demand for permanent magnets, but the cost and scarcity of rare-earth metals is an obstacle. Creating nanocomposites of rigidly exchange-coupled hard and soft magnets, for which the magnetization reversal occurs as in a single magneticphase material, is a promising route toward rare-earth-lean permanent magnets with high energy products. The hard/soft exch...

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“…Since both are equally undesired and detrimental to mechanical performance, only small parameterbandwidths are suitable to achieve a low level of defects. Besides improving manufacturable size, as is shown in, among others, by Mahbooba et al in [15] and the Heraeus GmbH in [16], further challenges and possibilities are still present. For instance, the mechanical properties of additively manufactured BMGs have not reached their cast reference yet.…”

Section: Introductionmentioning

confidence: 99%

“…Furthermore, the layer-wise built strategy and selective melting allow for local cooling rates largely to be decoupled from the actual part dimensions. Initially published by Pauly et al [7], investigating a Fe-based alloy, LPBF of various Zr-, Fe-, Al-, and Ti-based alloys have been reported in recent years [8][9][10][11][12][13][14][15]. One can conclude that adequate parameter selection may lead to sufficient cooling rates and hence amorphous solidification.…”

Section: Introductionmentioning

confidence: 99%

Mechanical Properties of Honeycomb Structured Zr-Based Bulk Metallic Glass Specimens Fabricated by Laser Powder Bed Fusion

Wegner

Frey

Stiglmair

et al. 2019

SAJIE

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Laser powder bed fusion of bulk metallic glasses offers great potential to overcome the existing restrictions of the geometrical size and complexity of bulk metallic glasses in conventional manufacturing routes due to high cooling rates during laser powder bed fusion. Bulk metallic glasses exhibit extraordinary strength, paired with high elasticity. Yet insights into additive manufactured bulk metallic glasses, especially of complex structures, are limited. The present article investigates the mechanical behaviour of Zrbased bulk metallic glasses, fabricated into honeycomb structures through laser powder bed fusion, by performing three-point bending tests. The results reveal a significant increase in specific strength, quasi-plasticity, and high elastic elongation. These structures thus offer great potential for lightweight applications and compliant mechanisms.

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Additive manufacturing of an iron-based bulk metallic glass larger than the critical casting thickness

Cited by 106 publications

References 37 publications

Additive Manufactured Large Zr-Based Bulk Metallic Glass Composites with Desired Deformation Ability and Corrosion Resistance

Additive Manufactured Large Zr-Based Bulk Metallic Glass Composites with Desired Deformation Ability and Corrosion Resistance

Rigid Exchange Coupling in Rare‐Earth‐Lean Amorphous Hard/Soft Nanocomposites

Mechanical Properties of Honeycomb Structured Zr-Based Bulk Metallic Glass Specimens Fabricated by Laser Powder Bed Fusion

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