Abstract
Forming complex geometries using the casting process is a big challenge for bulk metallic glasses (BMGs), because of a lack of time of the window for shaping under the required high cooling rate. In this work, we open an approach named the “entire process vacuum high pressure die casting” (EPV-HPDC), which delivers the ability to fill die with molten metal in milliseconds, and create solidification under high pressure. Based on this process, various Zr-based BMGs were prepared by using industrial grade raw material. The results indicate that the EPV-HPDC process is feasible to produce a glassy structure for most Zr-based BMGs, with a size of 3 mm × 10 mm and with a high strength. In addition, it has been found that EPV-HPDC process allows complex industrial BMG parts, some of which are hard to be formed by any other metal processes, to be net shaped precisely. The BMG components prepared by the EVP-HPDC process possess the advantages of dimensional accuracy, efficiency, and cost compared with the ones formed by other methods. The EVP-HPDC process paves the way for the large-scale application of BMGs.
Highlights
Bulk metallic glass (BMG) is always regarded as one of the most promising materials because of its ultrahigh strength, large elasticity, and excellent corrosion resistance, and can be applied in wide range of fields [1,2]
BMG plates solution proposed by Inoue et al [17,18], in the present horizontal EPV-High pressure die casting (HPDC), the melting of the with different thicknesses mother alloy is performed in an oxide crucible, which can avoid heating the metal by a sleeve and were cast directly in a multi-cavity mold using the EPV-HPDC method
These values are equal to the corresponding ones fabricated using copper mold suction-casting in the laboratory, confirming that fully glassy structures have been obtained using the EPV-HPDC process, even in the ZrCu-based BMG with a marginal glass-forming ability
Summary
Bulk metallic glass (BMG) is always regarded as one of the most promising materials because of its ultrahigh strength, large elasticity, and excellent corrosion resistance, and can be applied in wide range of fields [1,2]. A long-standing problem for this type of material is that it is difficult to mold into complex shapes using the casting method To overcome this bottleneck, several alternative approaches, such as thermoplastic forming (TPF) [3,4] and additive manufacturing (AM). High pressure die casting (HPDC) is a metal forming process that is widely used in real industry for forming aluminum, magnesium, zinc, and copper alloy components [15]. It possesses several advantages, such as a high cooling rate, high productivity, and the ability to form near net shapes.
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