EP3083090A2 - A method and system for fabricating bulk metallic glass sheets - Google Patents
A method and system for fabricating bulk metallic glass sheetsInfo
- Publication number
- EP3083090A2 EP3083090A2 EP14884848.4A EP14884848A EP3083090A2 EP 3083090 A2 EP3083090 A2 EP 3083090A2 EP 14884848 A EP14884848 A EP 14884848A EP 3083090 A2 EP3083090 A2 EP 3083090A2
- Authority
- EP
- European Patent Office
- Prior art keywords
- metallic glass
- bulk metallic
- feedstock
- rollers
- glass sheet
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Withdrawn
Links
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Classifications
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C45/00—Amorphous alloys
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21B—ROLLING OF METAL
- B21B3/00—Rolling materials of special alloys so far as the composition of the alloy requires or permits special rolling methods or sequences ; Rolling of aluminium, copper, zinc or other non-ferrous metals
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C33/00—Making ferrous alloys
- C22C33/003—Making ferrous alloys making amorphous alloys
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21B—ROLLING OF METAL
- B21B27/00—Rolls, roll alloys or roll fabrication; Lubricating, cooling or heating rolls while in use
- B21B27/06—Lubricating, cooling or heating rolls
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
- B21J1/00—Preparing metal stock or similar ancillary operations prior, during or post forging, e.g. heating or cooling
- B21J1/003—Selecting material
- B21J1/006—Amorphous metal
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C1/00—Making non-ferrous alloys
- C22C1/11—Making amorphous alloys
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C45/00—Amorphous alloys
- C22C45/003—Amorphous alloys with one or more of the noble metals as major constituent
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C45/00—Amorphous alloys
- C22C45/005—Amorphous alloys with Mg as the major constituent
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C45/00—Amorphous alloys
- C22C45/02—Amorphous alloys with iron as the major constituent
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C45/00—Amorphous alloys
- C22C45/04—Amorphous alloys with nickel or cobalt as the major constituent
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C45/00—Amorphous alloys
- C22C45/10—Amorphous alloys with molybdenum, tungsten, niobium, tantalum, titanium, or zirconium or Hf as the major constituent
Definitions
- the present invention relates generally to a method and apparatus for deforming metallic glasses to fabricate metallic glass sheets, strips and ribbons.
- BMGs Bulk metallic glasses
- BMGs which are also known as bulk solidifying amorphous alloy compositions, are a class of amorphous metallic alloy materials that are regarded as prospective materials for a vast range of applications because of their superior properties such as high yield strength, large elastic strain limit, and high corrosion resistance.
- SCLR super-cooled liquid region
- a larger ATsc is associated with a lower critical cooling rate, though a significant amount of scatter exists at ATsc values of more than 40°C.
- Bulk-solidifying amorphous alloys with a ATsc of more than 40°C, and preferably more than 60° C, and still more preferably a ATsc of 70°C and more are very desirable because of the relative ease of forming.
- the bulk solidifying alloy behaves like a high viscous fluid.
- the viscosity for bulk solidifying alloys with a wide supercooled liquid region decreases from 10 i2 Pa « s at the glass transition temperature to 10 7 Pa « s and in some cases to 10 5 Pa » s. Heating the bulk solidifying alloy beyond the crystallization temperature leads to crystallization and immediate loss of the superior properties of the alloy and it can no longer be formed.
- Superplastic forming (SPF) of an amorphous metal alloy involves heating it into the SCLR and forming it under an applied pressure.
- the method is similar to the processing of thermoplastics, where the formability, which is inversely proportional to the viscosity, increases with increasing temperature.
- the highly viscous amorphous metal alloy is metastable and eventually crystallizes.
- Crystallization of the amorphous metal alloy must be avoided for several reasons. First, it degrades the mechanical properties of the amorphous metal alloy. From a processing standpoint, crystallization limits the processing time for hot-forming operation because the flow in crystalline materials is order of magnitude higher than in the liquid amorphous metal alloy. Crystallization kinetics for various amorphous metal alloys allows processing times between minutes and hours in the described viscosity range. This makes the superplastic forming method a finely tunable process that can be performed at convenient time scales, enabling the net- shaping of complicated geometries.
- an amorphous metal alloy to be thermoplastically formed is described by its formability a parameter which is directly related to the interplay between the temperature dependent viscosity and time for crystallization. Crystallization has to be avoided during TPF of an amorphous metal alloy since it degrades the amorphous metal alloy's properties and retards its formability. Therefore, the total time elapsed during TPF of the amorphous metal alloy must be shorter than the time to crystallization.
- Sheets are one of the most important shapes of metals either as a final product or as feedstock for further processing.
- sheets are highly desirable since they are thin in one dimension and, in such geometries, bulk metallic glasses (BMGs) often show bending ductility.
- BMGs bulk metallic glasses
- fabrication of BMG sheets, especially large BMG sheets, has been challenging and the prior art has not demonstrated sheets exceeding about 10 cm x 10 cm in size.
- the resultant equilibrium sheet thickness is defined by the gravity and surface tension of the BMG melt and the molten bath.
- an inert gas environment and/or vacuum is required in the molten alloy chamber and the float chamber.
- the BMG melt is processed first through cold rolls for solidification casting and then through a subsequent set of hot rolls for hot rolling.
- This twin roll casting method solidifies t he BMG melts into sheets and must be done in v acuum or in an inert environment.
- the thickness of BMG sheets though twin roll casting is not desirable, as it is often non-uniform, with a typical thickness of less than about 200 ⁇ .
- Thermoplastic rolling by the subsequent set of rolls after twin roll casting also requires a very high rolling stress to further deform the thin sheets and achieve thinner sheets.
- the thickness is also not controllable (i.e., is non-uniform and typically below about 200 ⁇ ).
- the superplastic hot rolling step is only designed for smoothing the surface of the BMG sheets; it cannot deform the sheet due to the high hydrostatic stress state during hot rolling. Finally, no uni-axial thermoplastic stretching is applied.
- H is still another object of the present invention to fabricate bulk metallic glass sheets having complex patterns.
- the present invention relates generally to a method of fabricating a bulk metallic glass sheet, the method comprising the steps of:
- the present invention also relates generally to a system for fabricating a bulk metallic glass sheet, the system comprising:
- Figure 1 A, I B. 1 C and I D depict various methods of thinning metallic glasses in their supercooled liquid state.
- FIG. 2 depicts two methods of BMG processing technologies.
- Figures 3A and 3B demonstrate the relationship between formability and processing temperature.
- Figures 4A and 4B depict the effect of preheating on the maximum deformation that can be achieved during hot rolling with negligible stretching force.
- Figure 5 depicts a temperature protocol of a single step (conventional) processing protocol along with the processing protocol of the present invention.
- Figure 6 depicts a Time-Temperature-Transformation diagram for Z ⁇ Ti i jCuioNi ioBe ⁇ s
- Figure 7 depicts maximum dimensions of rolled Zr ⁇ Ti nCuioNi ioBe ⁇ s BMG sheets.
- Figure 8 depicts a schematic of a rolling system combined with a stretching method.
- Figure 9 depicts a comparison of the rolling force and stretching force for the same speed (3 mrn/s).
- Figure 1 0 depicts a comparison of the maximum shear stress and maximum hydrostatic pressure at thermoplastic rolling as a function of sheet thickness.
- Figure 1 1 A depicts an as rolled Zr4 4 Ti f BMG sheet and Figure 1 1 depicts the Z 4 4 Ti i iCu ioNi
- Figure 12 depicts a rolling apparatus for BMG material in accordance with the present invention.
- Figure 13 depicts an exploded view of the key components of the rolling apparatus in accordance with the present invention.
- Figure 14 depicts an example of the preheating plate in accordance with the present invention.
- Figure 1 5 depicts as-rolled Pd43NiioCu2 P 2 o samples.
- Figure 16 plots examples of making patterns in BMG sheets either in-plane or out-of- plane using a patterned roller
- Figure 1 7 depicts examples of making patterns in BMG sheets using thermoplastic compressing or blow molding methods.
- Figure 38 depicts an example of an eyeglass frame patterned into a BMG sheet processed in accordance with the present invention.
- Figure 19 depicts rolling of a sandwich of a bulk metallic glass feedstock material to join entirely (a) or partially (b) and deform the sandwich of material.
- the present invention relates generally to a method and apparatus for deforming metallic glasses under low force and stabilized conditions to fabricate large area bulk metallic glass sheets as well as bulk metallic glass strips and ribbons.
- sheet what is meant is a broad stretch or surface of bulk metallic glass.
- strip or “ribbon” what is meant is a long narrow piece of bulk metallic glass. In both instances, the bulk metallic glass sheet or strip is fabricated to have a thickness of less than about 1 mm.
- thermoplastic rolling the rolls are typically cold (-room temperature), which is much lower than the desired rolling temperature.
- room temperature the desired rolling temperature.
- a key aspect of the current invention is to establish the opposite - the BMG feedstock temperature increases when approaching the rolls and the amount by which it increases is optimized taking into consideration consumption of formability prior to contacting the rolls. This minimizes the time required to reach rolling temperature and optimizes viscosity during rolling to allow large deformations, enabling separation and laminar flow.
- thermoplastic rolling by itself does not allow for the fabrication of BMG sheets exceeding dimensions of 20 cm x 20 cm with a thickness of less than about 0.05 cm, even for those very few metallic glasses having a minimum practically achievable viscosity lower than 10 7 Pa-s.
- stretching deformation of BMGs is an effective use of deformation force where essentially all the exerted forces are used for deformation.
- instabilities necking
- the thickness variation is unacceptably high and worsens for multi-pass processing as illustrated in Figure 1 A.
- the present invention relates generally to a method and system for fabricating metallic glass sheets with controllable dimensions.
- Metallic glasses are deformed under low force and stabilized conditions to fabricate thin and large area metallic glass sheets.
- the present invention has the ability to produce metallic glass sheets that are both large (e.g., at least 20 cm x 40 cm, depending on the particular BMG) and thin (i.e., thicknesses of less than about 1 mm, preferably less than about 0.5 mm, most preferably less than about 0.1 mm, and even thinner, depending on the particular BMG).
- the present invention is based on a thermoplastic rolling technique which is optionally, but preferably, combined with stretching deformation, it is based on a combination of one or more of thermoplastic rolling and stretching combined with a pre-heating method.
- the predominant mode of deformation is dependent on the B G conditions such as thickness, viscosity, and crystallization time.
- the method described herein avoids crystallization during fabrication of the sheets, particularly with large and thin sheets made from BMGs having low I rmability as further described below. Through preheating, the available processing time that is consumed is reduced, which allows for the use of thick feedstock material. Deformation during hot-rolling is used to reduce thicknesses below we rely on only very limited deformation; minimum requirements are the smoothing of perturbations in the thickness.
- the present invention relates generally to a method of fabricating a bulk metallic glass sheet, the method comprising the steps of:
- the metallic glass is heated to a temperature of 0.8T g ⁇ T prc he at ⁇ 1 .4Tg (T g : glass transition temperature during heating with 20 K/min in °C) to pre-heat the feedstock BMG for the subsequent roiling step.
- This pre-heating step reduces heating time required for rolling and softens the BMG, which allows effective heat transfer between roller and BMG feedstock, and thereby rapid heating to the roller temperatures of 0.7T X ⁇ Tp ri XSS ⁇ 1 ,3T X (T x : crystallization temperature during heating with 20 K/min in °C).
- This pre-heating step becomes less effective (or can even be skipped) if the sheets are already thin, e.g., upon several passes when the thickness is below 1 mm.
- the BMG feedstock is hot-rolled at temperatures of 0.7T X ⁇ ⁇ ⁇ 0 ⁇ 5 « ⁇ 1 ⁇ 3 ⁇ ⁇ . Hot-rolling is used for thinning the feedstock but becomes very ineffective when
- the bulk metallic glass sheet Upon exiting of the bulk metallic glass sheet from the set of heated rollers, the bulk metallic glass sheet is optionally, but preferably, exposed to a stretching force. Surprisingly, this stretching force is typically much smaller than the clamping force required for hot-rolling of metallic glasses to achieve the same deformation rate. The stretching force is applied over a temperature gradient and the bulk metallic glass sheet moves with respect to the temperature gradient. This stabilizes the process and prevents instabilities from developing during the associated thinning.
- stretching occurs under velocity controlled conditions, not under force controlled conditions.
- all of the stretching force is used for tension deformation, while to achieve similar deformation rate during hot-rolling, a very large hydrostatic pressure must be exerted.
- the forces that are exerted to build the hydrostatic pressure do not thin the feedstock and can be considered as losses.
- the stretching force is dramatically smaller than the clamping force exerted during hot-rolling, particularly during the later stages where the BMG feedstock is thin.
- Such a method realization minimizes formabiiity consumption prior to the feedstock touching the rolls, and minimize required deformation stresses through a velocity controlled stretching in a temperature gradient that is stabilized and for thicker feedstock assisted by a hot- rolling processing step.
- Figure 1 A, I B, 1 C and ID depict various methods of thinning metallic glasses in their supercooled liquid state and in which stretching is achieved through velocity control (rather than force control).
- Figure 1 A (Case 1 ) illustrates constant stretching at a uniform temperature, resulting in overall necking of the feedstock and a non-uniform thickness.
- Figure I B (Case 2) illustrates a temperature gradient field using only stretching. As seen in Figure I B, the typical existence of surface defects on BMG feedstocks act as "perturbations" during stretching without hot rolling down a temperature gradient. These perturbations can continue to grow during stretching, resulting in local necking behavior.
- Figure 1 C illustrates that by hot rolling without stretching down a temperature gradient, very limited strain can be created to deform the BMG feedstocks due to a very high hydrostatic pressure in hot rolling.
- Figure 1 D illustrates that by combining hot rolling and stretching, perturbations can be highly eliminated and a much higher strain with a steady state thermoplastic deformation can be achieved.
- Figure 2 depicts two methods of BMG processing technologies.
- Route 1 is a liquid casting process that relies on fast quenching of liquid melts to form BMGs, while route 2 relies on thermoplastic forming of BMGs within the supercooled liquid state.
- Prior art techniques for fabricating BMG sheets which are based on liquid state processing are all conducted by the processing method of route 1.
- route 1 there are several main disadvantages of route 1 , such as very high temperature (above liquid temperature), rapid cooling to avoid crystallization (narrow processing window), the need for high vacuum or inert atmosphere, very limited control.
- route 2 processing technique may also be feasible to conduct in air.
- F temperature dependent formability
- Figures 3A and 3B formability increases with increasing processing temperature. This behavior is surprising and appears to be ubiquitous among BMGs.
- a wide range of BMGs have been studied, some of which are summarized in Pitt, E.B., G. Kumar, and J. Schroers, Temperature dependence of the thermoplastic formability in bulk metallic glasses. Journal of Applied Physics, (201 1 ) 1 10 (4).
- the present invention uses a processing protocol that optimizes the pre-rolling condition.
- Formability is low, yet the BMG feedstock softens sufficiently to enable rapid heating to rolling temperature (i.e., processing temperature within a specific temperature range) and also optionally, but preferably, uses stretch deformation as the major deformation process. Stretch deformation requires much lower forces than deformation during hot-rolling, and thus can deform at a lower temperature and conserve formability.
- the pre-heating of the BMG feedstock is an effective first processing step of the method described herein which leads to overall larger possible deformation that is obtainable by the processes of the prior art.
- the effect of pre-heating on the maximum deformation that can be achieved during hot-rolling with negligible stretch rolling forces (lateral sheet size) is schematically shown in Figures 4A and 4B.
- Figure 4 A depicts the maximum deformation that can be achieved during hot rolling without the use of any preheating. As shown in Figure 4A. without preheating the BMG feedstock only slowly heats to the desired rolling temperature, which causes slow deformation of the BMG feed stock, while consuming formability.
- the BMG feedstock instead of heating to the ideal rolling temperature directly the BMG feedstock is pre-heated, generally to a lower temperature first.
- the crystallization time is longer, and thus a significantly smaller fraction of formability is consumed as illustrated in Figures 3A and 3B.
- the present invention takes advantage of the exponential dependence of the crystallization time with temperature.
- the feedstock BMG is heated to a temperature where the crystallization time is very long, (i.e., at T g , the crystallization time is on the order of one day or more).
- this temperature is close to the processing temperature.
- the temperature of the pre-heated feedstock only has to be increased by a few tens of degrees through the set of heated rollers to achieve the processing temperature and rapid and precise heating can be achieved by feeding the pre-heated feedstock BMG through the set of heated rollers. Subsequently, cooling can be achieved through natural convection of the processing environment or can be enhanced by forcing gas or liquid on the exiting sheet.
- the use of the preheating step results in only a small overall deformation and can also cause damage to the rollers.
- the bulk metallic glass is preheated to a temperature where it can remain for a long period of time compared to its available time at processing temperature, which, in one embodiment is at least 5 times longer, preferably at least 10 times longer.
- the bulk metallic glass feedstock is preheated to a temperature sufficient to soften the bulk metallic glass feedstock but that does not significantly contribute to a consumed crystallization time of the bulk metallic glass.
- this pre-heating temperature is close to the rolling temperature from a thermal aspect, and the BMG feedstock has softened sufficiently that it can be thermoplastically deformed readily.
- Figure 6 illustrates a Time-Temperature-Transformation diagram for a Zr 4i )Ti ]
- Figure 7 illustrates the maximum rolled
- the initial feedstocks are all 1 .7 mm thick, 14 mm diameter discs. The number of passes prior to crystallization is indicated. As seen in Figure 7, using BMG, it determined that 440°C was the best processing temperature from a rolling point of view to yield the highest thickness reduction possible and thinnest samples possible.
- rolling is performed in several passes, which may range from between 3 and 1 5 passes.
- C H)Ni]oBe25 BMG exhibits a processing window of 5-6 minutes before crystallization.
- -25 seconds at 440°C are consumed for each pass among the total 5-6 minutes.
- the actual rolling depends on, for example, the sheet length, roller radius, rolling speed and, for typical BMG rolling, the actual rolling takes about 10 seconds. Therefore, rolling through 10 passes consumes approximately 6 minutes of processing time, meaning that the BMG sample would have already started to crystallize. The maximum is thus only about 9 passes before the BMG sample crystallizes.
- a non-ideal low processing temperature such as 420°C, 8 minutes of processing time is available, and thus more than 10 passes can be carried out before the sample crystallizes.
- the achieved deformation is low due to the significantly increased viscosity at this lower temperature.
- Other temperatures are also shown in Figure 7.
- the pre-heating temperature is optimized to a temperature that is high but that is low enough that it does not significantly contribute to the consumed crystallization time. This temperature is close to the processing/roll temperature so that the temperature can be rapidly raised to the processing temperature.
- the temperature is already close to the processing temperature, typically > T ru n - about 20% to about 35%, more preferably about 30%;
- the BMG feedstock can be rolled up to -16 passes before crystallization, as compared with ⁇ 10 passes for one-step processing.
- thermoplastic rolling only by thermoplastic rolling was it found that the forces required to reach a desired thickness reduction were dramatically high, in particular for sheet like dimensions (i.e., where the dimensions out-of-plane are far smaller than the dimensions in-plane).
- a stretching step is added as illustrated in Figure 8, then the thickness of sheet after exiting from the first set of rollers can be further reduced because of the stretching force, F.
- the stretching force can be applied by various methods, including, for example, by means of (1 ) a second pair of "cold" rollers (i.e., maintained at a lower temperature than the processing temperature of the heated rollers) which rotate at a higher velocity than the first set of heated rollers to create a stretching force; or (2) by a velocity controlled pulling mechanism.
- Other methods of applying a stretching force to the bulk metallic glass as it exits the first set of heated rollers would also be known to those skilled in the art. What is critical for stretching is both controlled velocity and a negative temperature gradient.
- the stress in the stretched part is proportional to ⁇ lh. This means that as the thickness of rolled sheet decreases, the driving stress will increase until the sheet breaks.
- variations in feedstock thickness can be reduced such that even some thickness perturbation prior to stretching can be tolerated without the BMG growing in an instable manner.
- Stretching is realized by precisely controlling the displacement. In other words, stretching is velocity controlled, as opposed to force controlled. Typically viscosity is at least substantially constant;
- Figure 8 illustrates schematics of a rolling system combined with a stretching method, where a second set of "cold” rollers is used to control stretching of the rolled sheet to make it thinner.
- thermoplastic rolling thickness reduction is from shear deformation (similar to squeezing flowing), while for stretching, thickness reduction is from tensile deformation.
- thermoplastic roiling and stretching forces can be calculated.
- the problem is simplified to a 2D problem, i.e., it was assumed that the thickness of sheet is far smaller than its other dimensions, and for BMGs deformed in the supercooled liquid region, the BMGs were considered as incompressible
- the pressure at rolling can be determined using a no-slip boundary condition as shown in Equation (1 ):
- ⁇ is the viscosity
- U is the rolling speed
- x is along the rolling direction
- h m , R, h ⁇ are the gap between rollers, radius of rollers and sheet thickness at exit respectively.
- the stretching force is estimated according to Equation (3):
- w is the width of sheet
- AU is the speed difference between the two ends of sheet
- La is the length within which the thickness reduction takes place.
- the deformation forces of thermoplastic rolling and stretching for the same deformation achieved during the deformation time differ by at least 10 times.
- Equation (3) it is obvious that all of the stretching force is used for plastic deformation, while for thermoplastic rolling, shear stress rather than hydrostatic pressure contributes to plastic deformation.
- the maximum shear stress and maximum hydrostatic pressure were compared for the same rolling parameters as in Figure 9 as function of thickness as shown in Figure 10. As illustrated in Figure 10, the maximum hydrostatic force increases dramatically last as the sheet thickness reduced. In addition the maximum hydrostatic force is always far larger than the maximum shear stress, which means that making thin sheets by thermoplastic rolling becomes less and less efficiency as the sheet thins. 15.
- One of the major benefits of the present invention is that it allows for the fabrication of sheets in an ambient atmosphere.
- most of the alternative methods previously proposed for fabricating sheet-like BMG parts including methods such as casting, twin-roll casting and alloy melt forming, require vacuum or an inert gas or reducing environment, which are impractical in a manufacturing environment.
- most BMGs oxidize during the suggested temperatures and processing conditions.
- it was surprising found that the oxidation is superficial and limited to the surface of the sheet. The oxide layer only stays on the top (thin) depth of the surface ( 1 -2 ⁇ ).
- Figure 1 1 A illustrates an as-rolled Zr 44 Ti
- oBe?5 BMG sheet with a thickness - 450 ⁇ (T ro n - 440 °C, Tp re - h lia i 420 °C for 13 passes).
- Figure ! I B illustrates this same BMG sheet after removing 1 -2 microns surface.
- the present invention is limited to processing conditions which result in laminar flow and avoids turbulences.
- Conditions for such flow can be defined through the Reynolds number, where a Reynolds number significantly smaller than 1 is required to result in laminar flow.
- the requirement of laminar ilow for the present invention include the following conditions: a rolling thickness of 10 ⁇ ⁇ ⁇ 20 mm; viscosity: 10 3 -10 !0 Pa « s, density: 3-20 g/cm 3 ; rolling speed: 1 -200 cm/min, respectively, all of which yields an Re ⁇ l 0 " l 3 -I 0- 3 «l .
- BMGs that can be processed in accordance with the present invention can be formally divided into four groups, even though they fall on a continuum as shown in Table 1.
- the need for stretching depends in part on the particular class of BMG as well as the desired size of the finished BMG sheet.
- BMGs with excellent formability exhibit a viscosity of 10 6 Pa » s at T x , Their formability is larger or equal to 10 " Pa " '.
- Pre-heating during the initial stages of rolling for thick feedstocks (> 3mm) is still required.
- the processing temperature can be chosen to be lower, and thus a larger processing time is available and crystallization can be more readily avoided.
- Stretching is required only for large sheets (i.e., having dimension greater than about 40 cm by about 20 cm).
- BMGs with high formability exhibit a viscosity of 10 6 ⁇ 10 7 Pa*s or smaller at T
- Their formability is between about 10 "4 ⁇ 10°.
- Pre-heating during the initial stages of rolling for thick feedstocks (> 3mm) is still required. Stretching is required for large and medium sheets (i.e., having dimension greater than about 20 cm by about 10 cm).
- BMG alloys with medium formability require stretching for most geometries. With a clamping force of 30 kN, the final size that can be achieved with these alloys is noticeably different than for the high formability BMGs. Large sheets can only be achieved through stretching. BMG sheets having dimensions of about 20 cm by about 10 cm are possible using the techniques described herein.
- BMG alloys low formability have a viscosity larger than 10 9 Pa s at T x (F ⁇ 10 "6 Pa "! ) have low formability and deform insignificantly during rolling. Thus, the vast majority of deformation must occur during stretching. Pre-shaped thin plates can be still thinned when including stretching. BMG sheets having dimensions of about 20 cm by about 3 cm are possible using the techniques described herein.
- Precise temperature control can be achieved by controlling the temperature of the heating elements.
- a thermocouple feedback can be placed inside the set of heated rollers and used to control the temperature of heating cartridges within the set of heated rollers.
- temperature control can also be accomplished using radiation heat from outside of the set of heated rollers. Rollers can also be heated by submersion in a heated liquid.
- Other temperature control means that allow for precise temperature control would also be known to those skilled in the art and are usable in the present invention.
- the rollers are heated with resistance heaters which are controlled through PID-control, in which thermocouples, positioned close to the surface of the rollers, are used to measure the temperature. It is highly desirable that temperature uniformity on the surface of the roll deviates less than 5 degrees Celsius throughout the whole roller,
- the pre-heater is a key element of the present invention because it reduces formability consumption of the BMG.
- the requirements for the pre-heater are that the BMG feedstock is sufficiently softened so that the BMG does not damage the roller, conforms to the roller shape, and meanwhile minimizes formability consumption.
- the preheater may comprise two heating plates (top and bottom) that heat the feedstock as the feedstock passes through the pre-heating step. Temperature control during pre-heating is critical, however not as critical as during rolling.
- the pre-heater optionally, but preferably, has a heating and control mechanism independent from that of the rollers. Techniques to heat and control the pre-heater can be similar to what has been suggested for the rollers.
- the preheater shown in Figure 1 1 allows for temperature control within ⁇ 5 degrees Celsius.
- the two heating plates press against feedstock simply by means of gravity.
- additional forces can be added. Such force can be adjusted to be higher or lower as is needed.
- the tendency of the BMG to stick to the rollers can be problematic. Sticking of the BMG to the rollers must be solved in order to maintain flatness, heat conductivity, and continuous formability during the entire rolling process.
- the tendency of the feedstock to stick to the rollers can be quantified by comparing the driving force to stick due to decreased system energy due to adhesion and the resistance force due to increased strain energy due to bending. For Newton fluid, the increased bending energy due to adhesion is shown in Equation (4):
- the present invention proposes the following strategies to reduce the sticking tendency of the BMG feedstock to the roller:
- Equation 7 Surface chemistry - when choosing a roller material that is poorly wetted by the BMG. What this means is that the wetting angle, ⁇ in Equation 7 is larger than 90 degrees (Equation 7 always holds). For example, nitrides and other ceramic roller surfaces reduce sticking (increase the wetting angle) whereas a metallic roller surface promotes sticking.
- Another way to prevent sticking of the BMG is to decrease the surface energy of BMG (j v in Equation (7)), by adding lubricants.
- Fig. 1 5 depicts photographs of as-rolled samples. As seen in Figure 1 5, the Pd 43 Ni I QC1127P20 sample may stick to the top and bottom rollers simultaneously causing it to tear along the centerline.
- the method described herein allows for the fabrication of ultrasmooth sheets of bulk metallic glasses with low oxidation rates.
- Figure 1 6 plots examples of making patterns in BMG sheets either in-plane or out-of-planc using a patterned roller.
- the BMG may be processed through a subsequent set of heated rollers having an in-plane or out-oi-plane pattern disposed thereon to pattern the BMG sheet.
- the set of patterned rollers are maintained at the same or a di fferent processing temperature as the first set of heated rollers to impose the pattern, either in-plane or out-of-plane. onto the BMG sheet.
- thermoplastic compressing or blow molding methods as illustrated in Figure 17.
- the BMG may be subjected to a compression molding or a blow molding process as is generally known in the art. Examples of these techniques are described, for example, in U.S. Pat. No. 8.641 ,839 to Schroers et al. and in U.S. Pat. Pub. No. 201 3/0306262 to Schroers et al., the subject matter of each of which is herein incorporated by reference in its entirety.
- the molding step may also be performed to mold the bulk metallic glass sheet into a mold cavity.
- a shearing step may be performed to cut the bulk metallic glass sheet into outlines set by the mold cavity.
- a deformation step may be performed to corrugate the bulk metallic glass sheet into out of plane deformations set by the mold cavity.
- the bulk metallic glass feedstock may comprise a plurality of bulk metallic glass pieces that are joined in step b).
- a plurality of bulk metallic glass pieces forming a "sandwich" may be joined by rolling.
- This joining step can be complete, in which the plurality of bulk metallic glass pieces are completely joined together without any gaps.
- the joining locations may be controlled to prevent the pieces of bulk metallic glass from joining in certain locations such that only portions of the bulk metallic glass pieces are joined.
- various materials such as salts and polymers can be interspersed within the bulk metallic glass pieces to prevent joining of the bulk metallic glass pieces in certain locations.
- Other methods that can prevent joining of materials in certain areas such that only portions of the bulk metallic glass pieces are joined may also be usable in the practice of the invention.
- the present invention also relates generally to a system for forming bulk metallic glass sheets from bulk metallic glass feedstock materials, the system comprising: a) a set of pre-heating plates, wherein the set of pre-heating plates are capable of sandwiching a bulk metallic glass feedstock therebetween to preheat the bulk metallic glass feedstock to a temperature sufficient to soften the bulk metallic glass feedstock but that does not significantly contribute to a consumed crystallization time of the bulk metallic glass;
- a stretching mechanism capable of stretching the rolled bulk metallic glass sheet exiting the set of heated rollers under controlled velocity.
- the stretching mechanism moves with respect to a negative temperature gradient, wherein as the bulk metallic glass is pulled or stretched from the set of heated rollers it cools to a temperature below the processing temperature of the BMG.
- the stretching mechanism comprises a velocity controlled pulling mechanism, wherein the velocity controlled pulling mechanism pulls the bulk metallic glass sheet as it exits from the set of heated rollers.
- This stretching mechanism preferably pulls the bulk metallic glass sheet at a faster rate than the bulk metallic glass proceeds through the set of heated rollers.
- the stretching mechanism comprises a set of set of rotatable cool rollers.
- the set of rotatable cool rollers are maintained at a lower temperature than the set of heated rollers and receive the bulk metallic glass sheet therebetween as it exits from the set of heated rollers.
- the set of cool rollers also preferably rotate at a faster rate than the set of heated rollers.
- the system of the invention may also comprise a set of rotatable patterned rollers that impose a pattern onto the bulk metallic glass sheet after it exits the stretching mechanism, in the alternative, following the rolling and stretching steps, various molding processes may be performed to impose a pattern onto the bulk metallic glass sheet.
- the system of the invention may comprise multiple systems connected in series to continuously produce a thin bulk metallic glass sheet.
- the system may comprise multiple stations of at least one additional set of heated rollers and at least one additional set of cool rollers, wherein the bulk metallic glass is further thinned.
- a set of preheater plates may be positioned before the at least one additional set of heated rollers.
- the preheater plates may not be necessary between every station if the bulk metallic glass sheet remains at a sufficient temperature for rolling between the set of heated rollers.
- the ''cool" rollers are only cool relative to the processing temperature maintained by the set of heated rollers.
- the set of heated rollers may optionally comprise a surface coating thereon that provides a smooth, non-stick surface, Other methods of preventing the bulk metallic glass from sticking to the heated rollers are discussed above.
- the set of heated rollers preferably comprise a hard metal that is sufficiently strong at the processing temperature of the bulk metallic glass.
- the set of cool rollers may have a rough surface, so that the set of cool rollers grip the bulk metallic glass sheet as it exits the set of heated rollers.
- FIGS 12 and 13 depict drawings of the preheater plates and the set of heated rollers in accordance with the present invention.
- preheater plates 2 and 4 are configured to receive the bulk metallic glass feedstock material.
- the preheater plates may sandwich the bulk metallic glass feedstock material using gravity alone or may optionally utilize an additional means of providing pressure to provide more intimate contact between the preheater plates and the bulk metallic glass feedstock material.
- Servo motors 6 control the rotation of the set of heated rollers 8 and 10.
- a load and displacement sensor 1 2 may be used to provide feedback on the position of the rollers.
- a set of jack screws can be used to control the gap between the set of heated rollers 8 and 10 based on information received from the load and displacement sensor 12.
- Figure 13 depicts a drawing of an exploded view of the key components of the rollers 8 and 10.
- cartridge heaters 16 are placed lengthwise along the rollers 8 and 10 along with thermocouples 1 8.
- the preheater plates 2 and 4 each also have cartridge heaters 20 and thermocouples going through them.
- Figure 14 depicts an example of the preheating plates 2 and 4 in accordance with the present invention.
- the measuring tape is in inches.
- the present invention allows for the fabrication of large, thin bulk metallic glass sheets having a uniform thickness.
- the present invention allows for the fabricating of bulk metallic glass strips having a uniform thickness.
- the present invention also allows for the further fabrication of complex patterns in the bulk metallic glass sheets, in addition, the present invention allows for the continuous fabrication of arbitrary complex shapes.
- the present invention also allows for the joining of bulk metallic glasses of the same type or of a different type by hot rolling.
- Other uses of the present invention to fabricate bulk metallic glass sheets having desired features, textures, thicknesses and configurations would also be known to those skilled in the art and are within the scope of the present invention.
Abstract
Description
Claims
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US201361919158P | 2013-12-20 | 2013-12-20 | |
US201462025558P | 2014-07-17 | 2014-07-17 | |
PCT/US2014/071408 WO2015134089A2 (en) | 2013-12-20 | 2014-12-19 | A method and system for fabricating bulk metallic glass sheets |
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US (1) | US20160346819A1 (en) |
EP (1) | EP3083090A4 (en) |
KR (1) | KR20160086946A (en) |
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JP6328097B2 (en) * | 2012-03-23 | 2018-05-23 | アップル インコーポレイテッド | Amorphous alloy roll forming of raw materials or component parts |
US20170087610A1 (en) * | 2015-09-30 | 2017-03-30 | Apple Inc. | Thermoplastic forming of cold rolled alloys |
EP3708270A1 (en) * | 2019-03-12 | 2020-09-16 | Heraeus Deutschland GmbH & Co KG | Mouldings with uniform mechanical properties comprising a metallic solid glass |
CN111468729B (en) * | 2020-04-06 | 2021-12-31 | 华中科技大学 | Powder rolling method and device for amorphous alloy |
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US4782994A (en) * | 1987-07-24 | 1988-11-08 | Electric Power Research Institute, Inc. | Method and apparatus for continuous in-line annealing of amorphous strip |
US5207962A (en) * | 1991-06-25 | 1993-05-04 | Applied Extrusion Technologies, Inc. | Method of making apertured film fabrics |
CN1327990C (en) * | 2002-09-27 | 2007-07-25 | 学校法人浦项工科大学校 | Method and apparatus for producing amorphous alloy sheet, and amorphous alloy sheet produced using the same |
WO2004028724A1 (en) * | 2002-09-27 | 2004-04-08 | Postech Foundation | Method and apparatus for producing amorphous alloy sheet, and amorphous alloy sheet produced using the same |
CN101257982A (en) * | 2005-09-08 | 2008-09-03 | 艾尔坎技术及管理有限公司 | Forming tools |
JP2009506895A (en) * | 2005-09-08 | 2009-02-19 | アルカン テヒノロギー ウント メーニッジメント リミテッド | Forming tool |
CN101675174A (en) * | 2007-02-13 | 2010-03-17 | 耶鲁大学 | Method for imprinting and erasing amorphous metal alloys |
US8298647B2 (en) * | 2007-08-20 | 2012-10-30 | California Institute Of Technology | Multilayered cellular metallic glass structures and methods of preparing the same |
CN101420826B (en) * | 2007-10-25 | 2012-10-10 | 鸿富锦精密工业(深圳)有限公司 | Case and surface treating method |
JP5775447B2 (en) * | 2008-03-21 | 2015-09-09 | カリフォルニア インスティテュート オブ テクノロジー | Formation of metallic glass by rapid capacitor discharge |
KR101394775B1 (en) * | 2010-04-08 | 2014-05-15 | 캘리포니아 인스티튜트 오브 테크놀로지 | Electromagnetic forming of metallic glasses using a capacitive discharge and magnetic field |
CN201669392U (en) * | 2010-05-18 | 2010-12-15 | 南昌市南方连铸工程有限责任公司 | Semi-solid casting-rolling double-roll type thin strip bloom conticaster |
JP5739549B2 (en) * | 2010-12-23 | 2015-06-24 | カリフォルニア・インスティテュート・オブ・テクノロジーCalifornia Institute Oftechnology | Sheet formation of metallic glass by rapid capacitor discharge |
US20130025746A1 (en) * | 2011-04-20 | 2013-01-31 | Apple Inc. | Twin roll sheet casting of bulk metallic glasses and composites in an inert environment |
JP5934366B2 (en) * | 2011-09-16 | 2016-06-15 | クルーシブル インテレクチュアル プロパティ エルエルシーCrucible Intellectual Property Llc | Molding and separation of bulk solidified amorphous alloys and composites containing amorphous alloys. |
SG11201405932YA (en) * | 2012-03-16 | 2014-10-30 | Univ Yale | Multi step processing method for the fabrication of complex articles made of metallic glasses |
JP5964639B2 (en) * | 2012-04-13 | 2016-08-03 | 株式会社中山アモルファス | Amorphous alloy plastic working method and plastic working apparatus |
US9375788B2 (en) * | 2012-05-16 | 2016-06-28 | Apple Inc. | Amorphous alloy component or feedstock and methods of making the same |
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- 2014-12-19 EP EP14884848.4A patent/EP3083090A4/en not_active Withdrawn
- 2014-12-19 US US15/106,487 patent/US20160346819A1/en not_active Abandoned
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US20160346819A1 (en) | 2016-12-01 |
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WO2015134089A2 (en) | 2015-09-11 |
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