Modelling and Simulation of Solidification Phenomena during Additive Manufacturing of Bulk Metallic Glass Matrix Composites (BMGMC)—A Brief Review and Introduction of Technique

Abstract

Despite a wealth of experimental studies focused on determining and improving mechanical properties and development of fundamental understanding of underlying mechanisms behind nucleation and growth of ductile phase precipitates from melt in glassy matrix, still, there is dearth of knowledge about how these ductile phases nucleate during solidification. Various efforts have been made to address this problem such as experiments in microgravity, high resolution electron microscopy and observation in synchrotron light after levitation but none have proved out to be satisfactory. In this study, an effort has been made to address this problem by modelling and simulation. Current state of the art of development, manufacturing, characterisation and modelling and simulation of bulk metallic glass matrix composites is described in detail. Evolution of microstructure in bulk metallic glass matrix composites during solidification in additive manufacturing has been presented with the aim to address fundamental problem of evolution of solidification microstructure as a result of solute partitioning, diffusion and capillary action. An overview is also presented to explain the relation of microstructure evolution to hardness and fracture toughness. This is aimed at overcoming fundamental problem of lack of ductility and toughness in this diverse class of materials. Quantitative prediction of solidification microstructure is done with the help of advanced part scale modelling and simulation techniques. It has been systematically proposed that 2-dimensional cellular automaton (CA) method combined with finite element (for thermal modelling) tools (CA-FE) programmed on FORTRAN  and parallel simulated on ABAQUS  would best How to cite this paper: Rafique, M.M.A. (2018) Modelling and Simulation of Solidification Phenomena during Additive Manufacturing of Bulk Metallic Glass Matrix Composites (BMGMC)-A Brief Review

Effect of Single Pass Laser Surface Treatment on Microstructure Evolution of Inoculated Zr<SUB>47.5</SUB>Cu<SUB>45.5</SUB>Al<SUB>5</SUB>Co<SUB>2</SUB> and Non-Inoculated Zr<SUB>65</SUB>Cu<SUB>15</SUB>Al<SUB>10</SUB>Ni<SUB>10</SUB> Bulk Metallic Glass Matrix Composites

“…In all three cases, the spot size was kept constant while the power and scan speed were varied to check their effect on final microstructure. An increase in laser power was assumed to exert more energy input, cause more turbulence in the melt pool, increase spatter [3], denudation zones [55] [76], evaporation and distort the surface structure with irregularities (shrinkage, segregation, lapping, cracks, porosity, pin and gas holes [3] [103]) produced during solidification [4] [104] [106] [107].…”

“…Components from nearly all types of metals and alloys can be produced by this technique (laser [58] [59] [60] [62] [63] or electron beam [64] [65] based) as the temperature obtained is a function of laser power and can be flexibly controlled over a wide range. Need and interest has also sparked in the use of this technique for microstructure control [54] [66] [67] [68], manipulation [69] [70] and manufacturing of parts by bulk metallic glasses and their composites [55] [67] [71] [72] [73]. Both simulation [55] [63] [65] [74]- [80] and experimental [64] [67] [68] [81] [82] methodologies have been rigorously applied to study, determine and ascertain the effect of various material and process parameters on final part quality and its properties.…”

“…Need and interest has also sparked in the use of this technique for microstructure control [54] [66] [67] [68], manipulation [69] [70] and manufacturing of parts by bulk metallic glasses and their composites [55] [67] [71] [72] [73]. Both simulation [55] [63] [65] [74]- [80] and experimental [64] [67] [68] [81] [82] methodologies have been rigorously applied to study, determine and ascertain the effect of various material and process parameters on final part quality and its properties. Different AM variants such as laser surface remelting [38] [94], welding [95] [96] [97], pulsing [98] [99], shock peening [100], and laser solid forming [66] [102] have been successfully applied to fabricate parts of various types, size, nature and geometries.…”

Effect of Inoculation on Phase Formation and Indentation Hardness Behaviour of Zr<SUB>47.5</SUB>Cu<SUB>45.5</SUB>Al<SUB>5</SUB>Co<SUB>2</SUB> and Zr<SUB>65</SUB>Cu<SUB>15</SUB>Al<SUB>10</SUB>Ni<SUB>10</SUB> Bulk Metallic Glass Matrix Composites

“…Bulk metallic glass matrix composites [1] [2] [3] have emerged as a potential material of future [4] bearing superior properties of strength [5], hardness [6] [7] [8] [9] [10] and elastic strain limit [11] [12] [13] which place them in an unique position in structural material family [14] [15]. Various applications have been proposed which make use of their superior properties [13].…”

“…Bulk metallic glass matrix composites [1] [2] [3] have emerged as a potential material of future [4] bearing superior properties of strength [5], hardness [6] [7] [8] [9] [10] and elastic strain limit [11] [12] [13] which place them in an unique position in structural material family [14] [15]. Various applications have been proposed which make use of their superior properties [13]. These include, targets of high speed moving projectiles [16] (such as wipple shield of international space station [11] [17] [18]), drill bits, parts of earth moving machinery [19], shape memory alloys [20] [21], and parts in cryogenic applications (such as gears of outer and deep space missions) [22] [23] [24].…”