JP6040251B2 - Injection molding of amorphous alloys using an injection molding system - Google Patents

Description

  The present disclosure relates to systems and methods for melting and forming meltable materials including amorphous alloys as a whole.

  Various methods are used for forming the molten metal material. For example, die casting generally involves injecting molten metal into a mold under high pressure. There are two typical methods used to inject molten metal into a mold: a cold chamber and a hot chamber. In the hot chamber method, a low melting point alloy is used in the gooseneck supply system and the injection mechanism is immersed in a molten metal bath. On the other hand, in the cold chamber method, a high melting point alloy (for example, an aluminum alloy) can be used, which can be melted in a crucible and then injected into the cold chamber. Some variations of the cold chamber include high pressure casting and semi-molten casting.

  Another method of forming and casting the material is called “metal injection molding”, or MIM, in which specific metal granules are mixed with a binder and molded before the binder is removed and sintered. Let

  One aspect of the present disclosure includes a melting zone configured to melt a meltable material received therein, and a plunger rod configured to inject the molten material from the melting zone into a mold. This plunger rod and melting zone is provided in-line and on a horizontal axis so that the plunger rod moves horizontally through the melting zone and moves the molten material into the mold Let

  Another aspect of the present disclosure includes a container having a body configured to receive a meltable material and to melt the material therein, and the molten material from the container through the transfer sleeve and into the mold. An injection molding system having a plunger rod configured to move, wherein the plunger rod, the container, and the transfer sleeve are provided in-line and on a horizontal axis, whereby the plunger rod is horizontal through the container. Move in the direction and move the molten material to the transfer sleeve.

  Yet another aspect of the present disclosure provides an injection molding system having a temperature controlled container, an induction source, a vacuum mold, and a plunger rod. The temperature controlled container has a body configured to receive the amorphous alloy material therein and to melt the amorphous alloy material therein, and to adjust the temperature of the container. It has one or more temperature control tubes configured to flow inside. The induction source is disposed adjacent to the temperature controlled container and is configured to melt the amorphous alloy material. The vacuum mold is configured to receive the molten amorphous alloy through the inlet and is configured to mold the molten amorphous alloy material under reduced pressure. The plunger rod is configured to inject molten amorphous alloy material from a temperature-controlled container body into a vacuum mold. The temperature-controlled container, vacuum mold inlet, and plunger rod are provided in-line and on a horizontal axis so that the plunger rod moves horizontally through the body of the temperature-controlled container and melts. Material is injected from the temperature controlled container into the vacuum mold via the inlet.

  Other features and advantages of the disclosure will be apparent from the following Detailed Description, the accompanying drawings, and the appended claims.

1 is a schematic diagram of an exemplary injection molding system according to one embodiment. FIG.

2 is a container and induction source that can be used in the melting zone of the system of FIG. 1 according to one embodiment.

FIG. 2 is a plan view of a vacuum mold that can be used with the system of FIG. 1 according to one embodiment. FIG. 4 is a cross-sectional view (cross section taken along line 4-4 of FIG. 3) of a vacuum mold that can be used with the system of FIG. 1 according to one embodiment.

FIG. 3 is a temperature-viscosity diagram of an exemplary bulk solidified amorphous alloy.

1 is a schematic diagram of a time-temperature-transformation (TTT) diagram for an exemplary bulk solidified amorphous alloy. FIG.

  The methods, techniques, and apparatus described herein are not intended to limit the described embodiments. All publications, patents, and patent applications cited herein are hereby incorporated by reference in their entirety.

  The articles “a” and “an” are used herein to refer to one or more (ie, at least one) grammatical objects of the article. By way of example, “a polymer resin” means one polymer resin or more than one polymer resin. Any ranges set forth herein are inclusive. As used throughout this specification, the terms “substantially” and “about” are used to describe and explain minor variations. For example, the terms are ± 2% or less, ± 1% or less, ± 0.5% or less, ± 0.2% or less, ± 0.1% or less, ± 0.05% or less, etc. Of ± 5% or less.

  As disclosed herein, a system (or apparatus or machine) is configured to perform injection molding of a material (eg, an amorphous alloy). The system is configured to process such materials or alloys by melting at a high melting temperature and then pouring the molten material into a mold and die casting. As will be described in detail below, the components of this system are placed in-line with each other. According to some embodiments, the components of the system (or access to the system) are along a horizontal axis.

  FIG. 1 shows a schematic diagram of such an exemplary system. More specifically, FIG. 1 shows an injection molding system 10. According to one embodiment, the injection molding system 10 is configured to inject a molten zone 12 configured to melt the meltable material received therein and the molten material from the melting zone 12 into the mold 16. And at least one plunger rod 14. At least the plunger rod 14 and the melting zone 12 are provided in-line and on a horizontal axis (eg, the X axis) so that the plunger rod 14 is substantially horizontally through the melting zone 12 (eg, along the X axis). The molten material is moved into the mold 16. The mold can be placed adjacent to the melting zone.

  The meltable material can be received in the melting zone in any number of forms. For example, the meltable material may be supplied to the melting zone 12 in the form of an ingot (solid state), semi-molten state, preheated slurry, powder, pellets, and the like. In some embodiments, a charging port (eg, the illustrated example of the ingot charging port 18) may be provided as part of the injection molding system 10. The charging port 18 may be a separate opening or region provided in the device at any number of locations. In one embodiment, the input port 18 may be a path through one or more parts of the device. For example, the material (eg, ingot) can be inserted horizontally into the container 20 by the plunger 14 or can be inserted horizontally from the mold side of the injection system 10 (eg, the mold 16 Through and / or through the transfer sleeve 30 into the container 20). In other embodiments, the meltable material can be fed into the melting zone 12 using other methods and / or other devices (eg, through the opposite side of the injection system).

  Melting zone 12 has a melting mechanism configured to receive a meltable material and hold it as it is heated to a molten state. The melting mechanism may be, for example, in the form of a container 20, which may have a body 22 configured to receive a meltable material and to melt the material therein. FIG. 2 shows an exemplary schematic of a container 20 that includes a body 22 (or base) for melting meltable material therein. The containers used throughout this disclosure are containers made of materials that have been employed to heat substances to high temperatures. For example, in one embodiment, the container may be a crucible, such as a boat crucible or a skull crucible. In one embodiment, the vessel 20 is a cryogenic hearth melting device that is configured to be available for meltable material under reduced pressure (eg, applied by a vacuum device 38 or a pump). In one embodiment, as described in detail below, the container is a temperature controlled container.

  The container 20 may also have an inlet for introducing material (eg, raw material) into the receiving or melting portion 24 of the body. In the embodiment shown in FIG. 2, the body 22 of the container 20 includes a substantially U-shaped structure. However, this illustrated shape is not meant to be limiting. The container 20 can include any number of shapes or configurations. The container body 22 may have a length and extend longitudinally and horizontally so that molten material is transported horizontally therefrom using the plunger 14. For example, the body can include a bottom with sidewalls extending vertically therefrom. The material for heating or melting can be received in the molten portion 24 of the container. The melted portion 24 is configured to receive meltable material to be melted therein. For example, the molten portion 24 has a surface for receiving material. The container 20 can receive material (eg, in the form of an ingot) within the melted portion 24 using one or more devices (eg, a loading port and a plunger) of the injection system for delivery.

  In one embodiment, the body 22 and / or its melted portion 24 can have a substantially rounded and / or smooth surface. For example, the surface of the melted portion 24 can be formed in an arc shape. However, the shape and / or surface of the main body 22 are not meant to be limiting. The body 22 may be a unitary structure or may be formed from separate parts that are joined or machined together. The body 22 may be formed from any number of materials (eg, copper, silver), including one or more coatings and / or configurations or designs. In one embodiment, the body 22 of the container 20 is formed of a meltable material / material that does not release or migrate contaminants into the molten material. For example, one or more surfaces may have a recess or groove therein.

  The body 22 of the container 20 may be configured to receive a plunger rod horizontally through the interior for moving the molten material. That is, in one embodiment, the melting mechanism is on the same axis as the plunger rod, and the body can be configured and / or dimensioned to receive at least a portion of the plunger rod. Thus, the plunger rod 14 can be configured to move the melted material (after heating / melting) from the container into the mold 16 by moving substantially through the container 20. Referring to the embodiment of the system 10 illustrated in FIG. 1, for example, the plunger rod 14 moves horizontally from right to left through the body 22 of the container 20 to move the molten material toward the mold 16. Move and push out.

  In order to heat the meltable zone 12 to melt the meltable material received in the container 20, the injection system 10 also includes a heat source that is used to heat and melt the meltable material. At least the molten portion 24 of the container, if not substantially the entire body 22 itself, is configured to be heated to melt the material received therein. Heating is accomplished, for example, using an induction source 26 disposed in the melting zone 12 that is configured to melt the meltable material. In one embodiment, the induction source 26 is disposed adjacent to the body 22 of the container 20. For example, as shown in FIG. 2, the induction source 26 may be substantially in the form of a coil disposed in a spiral around its length over a length of the body 22. Thus, the container 20 uses a power supply or power supply 28 to power the induction source / coil 26 to melt the meltable material (eg, the inserted ingot) in the melted portion 24 by electromagnetic induction. Configured. Induction coil 26 is configured to heat and melt any material contained in container 20 without melting and wetting container 20. The induction coil 26 radiates radio frequency (RF) waves to the container 20. As shown, the body 22 and the coil 26 surrounding the container 20 can be configured to be arranged horizontally along a horizontal axis (eg, the X axis).

  In one embodiment, the container 20 is a temperature controlled container. Such a container may include one or more temperature control tubes (eg, the cooling tube 25 shown in FIG. 2), which is used to adjust the temperature of the container (eg, to force the container to cool). , Configured to flow a liquid (eg, water or other fluid) through the interior. Such a forced cooled crucible may also be provided on the same axis as the plunger rod. The cooling pipe 25 serves to prevent the body 12 itself of the container 20 from overheating and melting. The cooling tube 25 serves to maintain the container at a temperature that prevents wetting of the molten / molten material (eg, molten amorphous alloy). The cooling tube can be connected to a cooling system configured to direct the flow of liquid within the container. The cooling tube 25 may include one or more inlets and outlets for liquid or fluid to flow therethrough. The inlet and outlet of the cooling pipe can be configured in any number of ways and is not meant to be limiting. For example, the cooling tube 25 may be disposed relative to the melted portion 24 so that the material therein melts and the container temperature is adjusted (ie, heat is absorbed and the container is cooled). Good. For example, in the embodiment illustrated in FIG. 2, for a boat or crucible container having a length and extending in the longitudinal direction, the molten portion 24 may also extend in the longitudinal direction. According to one embodiment, the cooling tube 25 may be disposed longitudinally with respect to the melted portion 24. For example, the cooling tube 25 can be located at the bottom of the body 22 (eg, below the material receiving surface). In another embodiment, the cooling tubes 25 can be arranged in a horizontal or lateral direction. The number, arrangement and / or orientation of the cooling tubes 25 should not be limited. The cooling liquid or cooling fluid may be configured to flow through the cooling tube 25 during melting of the meltable material when the induction source 26 is energized.

  The plunger 14 with the material melted in the container 20 can be extruded from the container 20 into the mold 16 to form the molten material into an object, part or component. In the case where the meltable material is an alloy (eg, an amorphous alloy), the mold 16 is configured to form a shaped bulk amorphous alloy object, part or component. Mold 16 has an inlet for receiving molten material therethrough. The outlet of the container 20 and the inlet of the mold 16 can be provided inline and on a horizontal axis so that the plunger rod 14 moves horizontally through the body 22 of the container and the molten material is transferred to the mold. Injection into the mold through 16 inlets.

  As mentioned above, systems such as the injection molding system 10 used to mold materials such as metals or alloys can utilize a vacuum when extruding molten material into a mold or die cavity. . The injection molding system 10 may further include at least one vacuum source 38 or pump configured to depressurize at least the melting zone 12 and the mold 16. At least a portion of the injection molding system 10 used to melt, move or transfer and mold the material therein may be depressurized. For example, the container 20, the transfer sleeve 30, and the plunger rod 14 may all be under reduced pressure and / or may be sealed in a vacuum chamber.

  In one embodiment, the mold 16 is a vacuum mold that is a hermetically sealed structure configured to adjust the internal vacuum (eg, by the valve 33) as the material is molded. FIGS. 3 and 4 illustrate one embodiment of a vacuum mold 16 that can be used with the injection molding system 10. For example, in one embodiment, the vacuum mold 16 is a first plate 32 (also referred to as an “A” mold or an “A” plate), a second plate 34 (“B” "Also called a mold or" B "plate), and a vacuum ejector box 36. The first plate 32 and the second plate 34 each have associated mold cavities 42 and 44 for molding the molten material therebetween. As shown in the exemplary cross-sectional view of FIG. 3, mold cavities 42 and 44 are configured to mold the molten material received therebetween through injection sleeve 30 or transfer sleeve. Mold cavities 42 and 44 may include part mold cavities for forming and casting parts therein.

  In general, the first plate 32 can be connected to the transfer sleeve 30. According to one embodiment, the plunger rod 14 is configured to move the molten material from the container 20 through the transfer sleeve 20 into the mold 16. A transfer sleeve 30 (sometimes referred to in the art as a cold sleeve or an injection sleeve) is provided between the melting zone 12 and the mold 16. The transfer sleeve 30 has an opening that is configured to receive molten material therethrough and transfer (using the plunger 14) into the mold 16. The opening may be provided in the horizontal direction along the horizontal axis (for example, the X axis). The transfer sleeve need not be a cold chamber. In one embodiment, at least the plunger rod 14, the container 20 (eg, its receiving or melting portion), and the opening of the transfer sleeve 30 are provided on an inline and horizontal axis so that the plunger rod 14 is in a molten material. Can be moved horizontally through the container 20 to move (and subsequently pass) into the opening of the transfer sleeve 30.

Referring to FIGS. 3 and 4, the first plate 32 may have an inlet for the mold 16 so that molten material can be inserted therein. The molten material is pushed horizontally through the transfer sleeve 30 and enters the mold cavity via an inlet between the first plate 32 and the second plate 34. During molding of the material, at least the first plate 32 and the second plate 34 are configured such that the material in between (eg, an amorphous alloy) is not substantially exposed to at least oxygen and nitrogen. Specifically, the pressure is reduced so that atmospheric air is substantially excluded from the plates 32 and 34 and the mold cavities 42 and 44. The inside of the vacuum mold 16 is depressurized using at least one vacuum source 32 connected to the vacuum line. For example, the vacuum or vacuum level of the system can be maintained at 13.3 to 0.013 Pa (1 × 10 ⁻¹ to 1 × 10 ⁻⁴ Torr) during melting and subsequent molding cycles. In another embodiment, this reduced pressure level is maintained between 1.33 and 0.013 Pa (1 × 10 ⁻² to about 1 × 10 ⁻⁴ Torr) during the melting and molding process. Of course, other pressure levels or ranges, for example, 0.13 μPa (1 × 10 ⁻⁹ Torr) to about 0.13 Pa (1 × 10 ⁻³ Torr), and / or 0.13 Pa (1 × 10 ⁻³ Torr). ˜13.3 Pa (0.1 Torr) can also be used.

  The vacuum ejector box 36 is disposed adjacent to at least the first plate 32 and the second plate 34. In one embodiment, the ejector box is sealed and configured to be vacuum sealed by reduced pressure from a vacuum source 38 (pump). In one embodiment, the sealed vacuum ejector box 36 includes an ejector mechanism 46 configured to remove molded (amorphous alloy) material from at least the mold cavity between the first plate 32 and the second plate 34. Is included. The ejector mechanism 46 can vacuum seal within a sealed vacuum ejector box 36 and any adjacent plate or interface that is sealed to the open face of the box 36. The ejector mechanism 46 may include an ejector plate 66 according to one embodiment. The ejector plate is configured to move within the sealed ejector box and remove the molded material from the mold 16. More specifically, the ejector plate 66 may have one or more (a plurality of) ejector pins (not shown) extending in a linear direction from itself. As the ejector plate 66 moves, the ejector pins also move relative to remove the molded material from the mold cavity of the mold 16. This ejector mechanism is associated with or connected to an actuating mechanism (not shown) that is configured to actuate to remove molded material or parts (eg, the reduced pressure between plates 32 and 34). After being released, after the first part 32 and the second part 34 have moved horizontally away from each other). The ejector pin can be configured to extrude the molded material from the mold cavity 44, for example.

  The mold 16 shown in FIGS. 3 and 4 is an example of a mold 16 that can be used with the injection molding system 10. It will be appreciated that other types of molds may be employed. For example, any number of additional plates can be provided between and / or adjacent to the first plate and the second plate to form the mold. For example, molds known as “A” series, “B” series, and / or “X” series molds may be attached to the injection molding system 10.

  In general, the injection molding system 10 can be operated in the following manner: The injection molding system 10 is depressurized. While maintaining the reduced pressure, a meltable material (eg, amorphous alloy or BMG) is charged into the supply mechanism (eg, charging port 18), a single ingot (raw material) is charged, inserted, and the container 20 is melted. The zone 12 (which is surrounded by an induction coil 26) is received. Using the “nozzle” stroke or plunger 14 of the injection molding apparatus, this material is moved into the molten portion 24 of the container 20 as needed. This material is heated by an induction process. In one embodiment, the injection molding apparatus controls the temperature via a closed loop system, thereby stabilizing the material at a particular temperature (eg, using a temperature sensor and controller). In another embodiment, the injection molding apparatus controls temperature via an open loop system. During heating / melting, the cooling system can be activated to allow (cooling) liquid to flow through the cooling tube of the container 20. Once the temperature for melting the meltable material is reached and maintained, the apparatus then moves the molten material from the container 20 through the transfer sleeve 20 into the vacuum mold 16 and horizontally along the horizontal axis. Infusion is started by moving in the direction (from right to left). This can be controlled using the plunger 14, which can be actuated using a servo driven drive or a hydraulic drive. The mold 16 is configured to receive the molten material through the inlet and is configured to mold the molten material under reduced pressure. That is, the molten material is injected into at least a mold cavity between the first plate and the second plate, and a part is molded by the mold 16. Once the mold cavity begins to fill, hold the vacuum (via the vacuum line and vacuum source 38) at a predetermined pressure to “fill” the molten material into the remaining cavity area within the mold cavity, Can be molded. After the molding process (for example, after about 10 to 15 seconds), the decompression to the mold 16 is released. For example, this pressure can be released using the vacuum break valve 33 and / or the vacuum port. The mold 16 is then opened to release the pressure and the parts are exposed to the atmosphere. The ejector mechanism 46 is operated to remove the solidified molded article from between at least the first plate and the second plate of the mold 16 (the ejector plate 66 is moved in a horizontal and linear direction via the actuator ( (For example, to the right), ejector pins assist in removing the part from the mold cavity). After this, the process can be started again. The mold 16 is closed by moving at least the first and second plates closer together, thereby allowing the first and second plates to be adjacent to each other. After pulling the plunger 14 back into the loading position, the melting zone 12 and the mold 16 are evacuated via a vacuum source to insert and melt more material and to mold another part.

  Thus, the embodiments disclosed herein illustrate an exemplary injection system having at least one plunger rod and an in-line melting system along a horizontal axis. This system does not require the use of a separate chamber for melting the metal and injecting the molten metal into the plunger cavity / cold sleeve as in known systems. This system does not require immersion of the plunger system in a molten metal bath, and reduction is reduced or does not require sintering. Furthermore, the raw material / inserted material and the final molded part volume are more precisely controlled, reducing heat loss. The system 10 is formed from an unmixed melt with low oxygen and low nitrogen (due to reduced pressure), thus allowing material molding that is substantially free of contaminants. Further, according to one embodiment, the meltable material is configured to be melted in a container that includes a surface that does not release contaminants, such that the material is substantially free of contaminants (eg, known Graphite crucibles can bring calvin particles into the melt). System 10 further provides a more efficient method of delivering the molding.

The disclosed system allows the injection molding of articles to be performed at a faster volume flow rate than plastic injection molding techniques (although it can be slower than conventional die casting machines). For example, casting flow rates using the systems described herein can be performed at about 0 to 1,000 cm ³ .

  Although not described in detail, the injection system of the present disclosure includes one or more sensors, flow meters, etc. (eg, for monitoring temperature, coolant flow, etc.) and / or one or more controllers. Additional parts that are not limited to may be included. Further, when under reduced pressure, to any number of parts or adjacent to assist in melting and forming part of the molten material by substantially limiting or eliminating significant air exposure or leakage. And a sealing part may be provided. For example, the seal can be in the form of an O-ring. A seal can be made of any material and is defined as a device that stops a substance (eg, air) from moving between the parts to be sealed. The injection system may perform an automated or semi-automated process for inserting meltable material therein, depressurizing, heating, injecting, and molding the material to form a part.

  The material molded (and / or melted) using any embodiment of the injection system disclosed herein may include any number of materials and should not be limited. . In one embodiment, the material molded using the injection molding system 10 of the present disclosure is an amorphous alloy, which is a metal that can behave like a plastic, or an alloy with a liquid atomic structure.

  Bulk solidified amorphous alloys, or bulk metallic glass (“BMG”), is a recently developed class of metallic materials. These alloys can be solidified and cooled at a relatively moderate rate, and they maintain an amorphous, amorphous (ie, vitreous) state at room temperature. Amorphous alloys have many superior properties than their crystalline counterparts. However, if the cooling rate is not sufficiently high, crystals may form within the alloy during cooling, and so the benefits of the amorphous state may be lost. For example, one important challenge associated with the manufacture of bulk amorphous alloy parts is the partial crystallization of those parts, either by slow cooling or by impurities in the alloy raw material. Within a BMG part, a high degree of amorphization (and conversely a low degree of crystallinity) is desirable, so a method for casting BMG parts with a controlled amount of amorphization needs to be developed. There is sex.

  FIG. 5 (obtained from US Pat. No. 7,575,040) shows exemplary bulk solidification from the VIT-001 series of the Zr--Ti--Ni--Cu--Be family manufactured by Liquidmetal Technology. The viscosity-temperature graph of an amorphous alloy is shown. It should be noted that there is no clear liquid / solid transformation for bulk solidifying amorphous metals during the formation of amorphous solids. This molten alloy becomes increasingly viscous with increasing supercooling until it approaches a solid form near the glass transition temperature. Thus, the temperature of the solidification front for a bulk solidified amorphous alloy can be near the glass transition temperature, where it actually acts as a solid for the purpose of drawing the quenched amorphous sheet product.

  FIG. 6 (obtained from US Pat. No. 7,575,040) shows a time-temperature-transformation (TTT) cooling curve, or TTT diagram, of an exemplary bulk solidified amorphous alloy. Bulk solidified amorphous metals, like conventional metals, do not undergo liquid / solid crystallization transformations upon cooling. Instead, the more fluid, amorphous form of metal observed at high temperatures (near the “melting temperature” Tm) becomes more viscous as the temperature is reduced (to near the glass transition temperature Tg). Eventually exhibiting the external physical properties of conventional solids.

  For bulk solidified amorphous metals, the “melting temperature” Tm can be defined as the thermodynamic liquid phase temperature of the corresponding crystal phase, even though there is no liquid / crystallization transformation. Under this regime, the viscosity at the melting temperature of the bulk solidified amorphous alloy can range from about 0.1 poise to about 10,000 poise, and in some cases, less than 0.01 poise. . This lower viscosity at the “melting temperature” results in faster and complete filling of complex parts of the shell / mold with bulk solidified amorphous metal to form BMG parts. Further, the cooling rate of the molten metal to form the BMG part is such that the time-temperature profile during cooling does not cross the nose shaped region that bounds the crystallization region in the TTT diagram of FIG. There must be. In FIG. 6, T nose is the critical crystallization temperature Tx where crystallization is most rapid and occurs on the shortest time scale.

The supercooled liquid region, Tg-Tx temperature region, demonstrates extreme stability against crystallization of the bulk solidified alloy. Within this temperature range, the bulk solidified alloy can exist as a highly viscous liquid. The viscosity of the bulk solidified alloy in this supercooled liquid region ranges from 10 ¹² Pa · s at the glass transition temperature to 10 ⁵ Pa · s at the high temperature limit of the supercooled liquid region, which is the crystallization temperature. Can vary between. A liquid having such a viscosity can experience substantial plastic strain under pressure. Embodiments herein utilize the large plastic formability within this supercooled liquid region as a forming and separating method.

  It is necessary to clarify Tx. Technically, the nose shaped curve shown in the TTT diagram describes Tx as a function of temperature and time. Therefore, Tx is reached when it hits this TTT curve, regardless of the trajectory followed during heating or cooling of the metal alloy. In FIG. 5 (b), Tx is shown as a dashed line because Tx can vary from proximal Tm to proximal Tg.

  The schematic TTT diagram of FIG. 6 shows a die casting processing method of Tm or more to less than Tg in which a time-temperature locus (shown as (1) as an exemplary locus) does not hit the TTT curve. During die casting, this shaping is performed at the same time as the rapid cooling to avoid the trajectory hitting the TTT curve. Time-temperature trajectory (shown as exemplary trajectories (2), (3) and (4)) does not hit the TTT curve, and processing related to superplastic forming (SPF) from Tg or less to less than Tm Method. In SPF, amorphous BMG is reheated into the supercooled liquid region and the available processing window can be much larger than die casting, resulting in better process controllability. The SPF process does not require rapid cooling to avoid crystallization during cooling. Also, as shown by exemplary trajectories (2), (3), and (4), SPF is performed with the highest temperature during SPF being above or below T nose and up to about Tm can do. Although the temperature of one amorphous alloy is raised, when it is managed so as to avoid hitting the TTT curve, Tx is not reached even when heated to “Tg to Tm”.

  The typical differential scanning calorimeter (DSC) heating curve of bulk solidified amorphous alloys, obtained at a heating rate of 20 ° C./min, largely describes the specific trajectory across the TTT data. There will be a Tg at temperature, a Tx where the DSC heating ramp intersects the onset of TTT crystallization, and finally a melting peak where the same trajectory intersects the temperature range for melting. Avoid TTT curves completely when heating bulk solidified amorphous alloys at a rapid heating rate as shown by the upslopes of trajectories (2), (3), and (4) in FIG. And DSC data show a glass transition upon heating but no Tx. Another way of thinking about this is that the trajectories (2), (3), and (4) are within the TTT curve nose (and further above) to the temperature of the Tg line, as long as they do not hit the crystallization curve It can fit in any place. That simply means that as the processing temperature increases, the horizontal flats in the trajectory can become much shorter.

Phase As used herein, the term “phase” can refer to what can be found in a thermodynamic phase diagram. A phase is a region of space (eg, a thermodynamic system) throughout which all physical properties of the material are essentially uniform. Examples of physical properties include density, refractive index, chemical composition, and lattice periodicity. A simple description of a phase is a region of material that is chemically uniform, physically distinct, and / or mechanically separable. For example, in a system consisting of ice and water in a glass jar, the ice cube is one phase, water is the second phase, and humid air above the water is the third phase. Jar glass is another separate phase. A phase can refer to a solid solution that can be a two-component, three-component, four-component or higher solution or compound, such as an intermetallic compound. As another example, the amorphous phase is completely different from the crystalline phase.

Metals, transition metals, and non-metals The term “metal” refers to an electropositive chemical element. As used herein, the term “element” generally refers to an element that can be found in the periodic table. Physically, a ground state metal atom includes a partially filled band with an empty state close to the occupied state. The term “transition metal” is the third in the periodic table that has an incomplete internal electron shell and serves as a transition link between the most electropositive and the least electropositive in a set of elements. It is one of the metal elements within the range of Group 12 to Group 12. Transition metals are characterized by multiple valences, colored compounds, and the ability to form stable complex ions. The term “nonmetal” refers to a chemical element that does not have the ability to lose electrons and form a cation.

  Depending on the application, any suitable non-metallic elements, or combinations thereof, can be used. An alloy (or “alloy composition”) may include a plurality of non-metallic elements, such as at least two, at least three, at least four or more non-metallic elements. The nonmetallic element can be any element found within Groups 13-17 in the periodic table. For example, the nonmetallic elements are F, Cl, Br, I, At, O, S, Se, Te, Po, N, P, As, Sb, Bi, C, Si, Ge, Sn, Pb, and B. It can be any one of them. In some cases, the non-metallic element can refer to a specific metalloid within Group 13 to Group 17 (eg, B, Si, Ge, As, Sb, Te, and Po). In one embodiment, the non-metallic element can include B, Si, C, P, or a combination thereof. Thus, for example, the alloy can include borides or carbides, or both.

  Transition metal elements are scandium, titanium, vanadium, chromium, manganese, iron, cobalt, nickel, copper, zinc, yttrium, zirconium, niobium, molybdenum, technetium, ruthenium, rhodium, palladium, silver, cadmium, hafnium, tantalum, tungsten , Rhenium, osmium, iridium, platinum, gold, mercury, rutherfordium, dobnium, seaborgium, bolium, hassium, mitonium, ununnilium, ununnium, and ununbium. In one embodiment, the transition metal element-containing BMG is Sc, Y, La, Ac, Ti, Zr, Hf, V, Nb, Ta, Cr, Mo, W, Mn, Tc, Re, Fe, Ru, Os, It may have at least one of Co, Rh, Ir, Ni, Pd, Pt, Cu, Ag, Au, Zn, Cd, and Hg. Depending on the application, any suitable transition metal element, or combinations thereof, can be used. The alloy composition may include a plurality of transition metal elements, such as at least 2, at least 3, at least 4 or more transition metal elements.

  An alloy or alloy “sample” or “specimen” alloy described herein may have any shape or size. For example, the alloy can have a particulate shape, which can have a shape such as a sphere, ellipse, wire, rod, sheet, flake, or irregular shape. The microparticles can have any size. For example, the microparticles can be about 5 micrometers to about 80 micrometers, such as about 10 micrometers to about 60 micrometers, such as about 15 micrometers to about 50 micrometers, such as about 15 micrometers to about 45 micrometers, etc. It may have an average diameter of about 1 micrometer to about 100 micrometers, such as about 25 micrometers to about 35 micrometers, such as about 20 micrometers to about 40 micrometers. For example, in one embodiment, the average diameter of the microparticles is from about 25 micrometers to about 44 micrometers. In some embodiments, smaller particles, such as those in the nanometer range, or larger particles, such as those larger than 100 micrometers, can be used.

  The alloy sample or specimen can also be of much larger dimensions. For example, it can be a bulk structural component such as an ingot, an electronics enclosure / casing, or even a portion of a structural component having dimensions in the millimeter, centimeter, or meter range.

Solid solution The term “solid solution” refers to a solid form of a solution. The term “solution” refers to a mixture of two or more substances that can be a solid, liquid, gas, or a combination thereof. This mixture can be homogeneous or heterogeneous. The term “mixture” is a composition of two or more substances that can be combined with each other and generally separated. In general, the two or more substances are not combined with each other.

Alloys In some embodiments, the alloy compositions described herein can be fully alloyed. In one embodiment, an “alloy” refers to a homogenous mixture or solid solution of two or more metals in which one atom replaces another atom or occupies an interstitial position between atoms. For example, brass is an alloy that is an alloy of zinc and copper, as opposed to a composite material, which is partially or completely of one or more elements in a metal matrix, such as one or more compounds in the metal matrix. A solid solution. The term alloy herein may refer to both a fully solid solution alloy that may exhibit a single solid phase microstructure and a partial solution that may exhibit two or more phases. The alloy compositions described herein can refer to those comprising an alloy or those comprising an alloy-containing composite material.

  Thus, a fully alloyed alloy can have a homogeneous distribution of its constituents, whether in solid solution phase, compound phase, or both. As used herein, the term “fully alloyed” can describe slight variations within tolerances. For example, the term includes at least 90% alloying, such as at least 95% alloying, such as at least 99% alloying, such as at least 99.5% alloying, such as at least 99.9% alloying. Can point. Percentages herein can refer to either volume percentages or weight percentages, depending on the context. These percentages can be balanced by impurities, which can be in terms of compositions or phases that are not part of the alloy.

Amorphous or Amorphous Solid An “amorphous” or “amorphous solid” is a solid that lacks the lattice periodicity characteristic of crystals. As used herein, “amorphous solid” includes “glass”, which is an amorphous solid that softens and transforms into a liquid state upon heating through the glass transition. In general, amorphous materials lack the long-range order characteristic of crystals, but these amorphous materials can possess some short-range order on the atomic length scale due to the nature of chemical bonds. A distinction between an amorphous solid and a crystalline solid can be made based on lattice periodicity determined by structural property evaluation techniques such as X-ray diffraction and transmission electron microscopy.

  The terms “order” and “disorder” indicate the presence or absence of any symmetry or correlation within a multiparticulate system. The terms “long-range order” and “short-range order” distinguish order within a material based on a length scale.

  The most exact form of order in a solid is lattice periodicity. A specific pattern (the arrangement of atoms in the unit cell) is repeated many times to form a translationally invariant, space filling. This lattice periodicity is a defining characteristic of crystals. The possible symmetries are grouped into 14 Bravey lattices and 230 space groups.

  Lattice periodicity suggests long-range order. If only one unit cell is known, its translational symmetry makes it possible to accurately predict all atomic arrangements at an arbitrary distance. The converse is generally true, except in the case of, for example, quasicrystals that have a completely deterministic filling but do not possess lattice periodicity.

Long-range order characterizes a physical system in which remote parts of the same sample exhibit correlated behavior. This long-range order can be expressed as a correlation function, that is, the next spin-spin correlation function.

  In the above function, s is a spin quantum number and x is a distance function in a specific system. This function is equal to the identity element when x = x ′ and decreases as the distance | x−x ′ | Typically, this function decays exponentially to zero over long distances and the system is considered disordered. However, if this correlation function decays to a constant value with a large | x−x ′ |, it can be stated that the system possesses long-range order. If this function decays to zero as a power of distance, it can be called quasi-long-range order. Note that what constitutes a large value of | x-x '| is relative.

  A system can be extended by presenting a quenching disorder, eg, spin glass, if some of the parameters that define its behavior are random variables that do not evolve over time (ie, they are quenched or frozen). it can. This quenching disorder is the opposite of the annealing disorder in which the random variable itself can develop. Embodiments herein include systems that include a quenching disorder.

  The alloys described herein can be crystalline, partially crystalline, amorphous, or substantially amorphous. For example, an alloy sample / specimen can include at least some degree of crystallinity, and the grains / crystals have a size in the nanometer and / or micrometer range. Alternatively, the alloy can be substantially amorphous, such as sufficiently amorphous. In one embodiment, the alloy composition is substantially crystalline, such as fully crystalline, and at least not substantially amorphous.

  In one embodiment, the presence of one or more crystals in another amorphous alloy can be interpreted as a “crystalline phase” in that alloy. The degree of crystallinity of an alloy (or in some embodiments, “crystallinity” for short) can refer to the amount of crystalline phase present in the alloy. The degree can refer, for example, to the fraction of crystals present in the alloy. This fraction can refer to a volume fraction or a weight fraction, depending on the context. A measure of how “amorphous” an amorphous alloy can be is the degree of amorphization. The degree of amorphization can be measured from the viewpoint of the degree of crystallinity. For example, in one embodiment, an alloy having a low degree of crystallinity can be described as having a high degree of amorphousness. In one embodiment, for example, an alloy having 60% by volume crystalline phase may have 40% by volume amorphous phase.

Amorphous alloy or amorphous metal "Amorphous alloy" means an amorphous content of more than 50% by volume, preferably more than 90% by volume, more preferably more than 95% by volume, most preferably 99% by volume. An alloy having an amorphous content of from super to almost 100% by volume. As noted above, it should be noted that alloys with a high degree of amorphization have an equally low degree of crystallinity. An “amorphous metal” is an amorphous metal material having a disordered atomic scale structure. By being crystalline, amorphous alloys are amorphous, as opposed to most metals, which have a highly ordered atomic arrangement. The material in which such a disordered structure is created directly from the liquid state during cooling may be referred to as “glass”. Thus, amorphous metals are commonly referred to as “metallic glass” or “glass metal”. In one embodiment, bulk metallic glass (“BMG”) can refer to an alloy whose microstructure is at least partially amorphous. However, in addition to extreme rapid cooling, there are several ways to create amorphous metals, including physical vapor deposition, solid phase reaction, ion irradiation, melt spinning, and mechanical alloying. Amorphous alloys can be a single class of materials regardless of how they are prepared.

  Amorphous metal can be produced through various quenching methods. For example, amorphous metal can be created by sputtering molten metal onto a rotating metal disk. A quench of about several million degrees per second can be too fast for crystals to form, so that the metal is “fixed” in the glassy state. Amorphous metals / alloys can also be created with critical cooling rates that are slow enough to allow the formation of thick layer amorphous structures, such as bulk metallic glass.

  The terms “bulk metallic glass” (“BMG”), bulk amorphous alloy (“BAA”), and bulk solidified amorphous alloy are used interchangeably herein. These terms refer to an amorphous alloy having a minimum dimension in the range of at least millimeters. For example, the dimension is at least about 0, such as at least about 1 mm, at least about 2 mm, at least about 4 mm, at least about 5 mm, at least about 6 mm, at least about 8 mm, at least about 10 mm, at least about 12 mm, etc. .5 mm. Depending on the geometry, the dimensions can refer to diameter, radius, thickness, width, length, etc. The BMG may also be a metallic glass having at least one dimension in the centimeter range, such as at least about 1.0 cm, such as at least about 2.0 cm, such as at least about 5.0 cm, such as at least about 10.0 cm. You can also. In some embodiments, the BMG may have at least one dimension in the range of at least meters. BMG can exhibit any of the shapes or forms described above with respect to metallic glass. Accordingly, the BMG described herein may differ from thin films made by conventional deposition techniques in one important aspect in some embodiments, the former BMG being the latter The size can be much larger than that of the thin film.

  The amorphous metal can be an alloy rather than a pure metal. This alloy can contain atoms of significantly different sizes, resulting in a low free volume in the molten state (and therefore has a viscosity that is orders of magnitude higher than other metals and alloys). . This viscosity prevents atoms from moving sufficiently to form an ordered lattice. This material structure can provide low shrinkage during cooling and resistance to plastic deformation. This absence of grain boundaries, which in some cases is a weakness of crystalline materials, can result in better resistance to wear and corrosion, for example. In one embodiment, although technically glass, amorphous metals can also be much stronger and less brittle than oxide glasses and ceramics.

  The thermal conductivity of amorphous materials can be lower than the thermal conductivity of their crystalline counterparts. In order to achieve the formation of an amorphous structure even during slower cooling, an alloy is made with three or more components, resulting in a composite crystal unit with higher potential energy and lower probability of formation. be able to. The formation of an amorphous alloy depends on several factors: the composition of the alloy components and the atomic radii of the components (preferably greater than 12% in order to achieve high packing density and low free volume). And the negative heat of mixing of the combination of components that prevents crystal nucleation and extends the time that the molten metal remains supercooled. However, since the formation of an amorphous alloy is based on a wide variety of variables, it may be difficult to determine in advance whether the alloy composition forms an amorphous alloy.

  For example, amorphous alloys of boron, silicon, phosphorus, and other glass formers with magnetic metals (iron, cobalt, nickel) can be magnetic with low coercivity and high electrical resistance. This high resistance results in a low loss due to eddy currents when exposed to an alternating magnetic field, which is a characteristic useful as, for example, a transformer core.

  Amorphous alloys can have a variety of properties that are potentially useful. Specifically, amorphous alloys tend to be stronger than crystalline alloys of similar chemical composition, and they can withstand greater reversible ("elastic") deformation than crystalline alloys. Amorphous metals derive their strength directly from their amorphous structure, which can have no defects (such as dislocations) that limit the strength of the crystalline alloy. For example, one state-of-the-art amorphous metal, known as Vitreloy ™, has a tensile strength approximately twice that of high-grade titanium. In some embodiments, the metallic glass at room temperature is not ductile and breaks suddenly when tension is applied, which is not evident in imminent failure, so in applications where reliability is important, Limit applicability of the material. Therefore, to overcome this challenge, metal matrix composites with a metallic glass matrix containing ductile crystalline metal dendritic particles or fibers can be used. Alternatively, BMG with less elements (eg, Ni) that tend to cause seriousness can be used. For example, by using BMG that does not contain Ni, the ductility of the BMG can be improved.

  Another useful property of bulk amorphous alloys is that they can be intrinsic glasses, in other words, bulk amorphous alloys can soften and flow when heated. This allows easy processing, such as by injection molding, in much the same way as a polymer. As a result, amorphous alloys can be used to make sports equipment, medical devices, electronic components and equipment, and thin films. Amorphous metal thin films can be deposited as protective coatings via high speed oxygen fuel technology.

  The material can have an amorphous phase, a crystalline phase, or both. These amorphous and crystalline phases can have the same chemical composition and differ only in microstructure (ie, one is amorphous and the other is crystalline). Microstructure in one embodiment refers to the structure of the material as revealed by a microscope with a magnification of 25X or higher. Alternatively, these two phases can have different chemical compositions and microstructures. For example, the composition can be partially amorphous, substantially amorphous, or fully amorphous.

  As described above, the degree of amorphization (and conversely, the degree of crystallinity) can be measured by the fraction of crystals present in the alloy. The degree can refer to the volume fraction or weight fraction of the crystalline phase present in the alloy. A partially amorphous composition includes at least about 10%, such as at least about 20%, such as at least about 40%, such as at least about 60%, such as at least about 80%, such as at least about 90%. , Which can refer to a composition at least about 5% by volume of which is in an amorphous phase. The terms “substantially” and “about” are defined elsewhere in this specification. Thus, a composition that is at least substantially amorphous includes at least about 99.8 vol%, such as at least about 95 vol%, such as at least about 98 vol%, such as at least about 99 vol%, such as at least about 99.5 vol%. %, Such as at least about 99.9% by volume, at least about 90% by volume of which is amorphous. In one embodiment, the substantially amorphous composition can have any attendant minor crystalline phase present therein.

  In one embodiment, the amorphous alloy composition can be homogeneous with respect to the amorphous phase. A substance with a uniform composition is homogeneous. This is in contrast to materials that are heterogeneous. The term “composition” refers to the chemical composition and / or microstructure in a substance. A substance is homogeneous when the volume of the substance is divided in half and both halves have substantially the same composition. For example, a particulate suspension is homogeneous when the volume of the particulate suspension is divided in half and both halves have substantially the same volume of particles. However, it may be possible to see individual particles under a microscope. Another example of a homogeneous material is air, where the various components in the air are equally floating, but the particles, gases, and liquids in the air can be analyzed separately or separated from the air. You can also.

  A composition that is homogeneous with respect to an amorphous alloy can refer to one having an amorphous phase that is distributed substantially uniformly throughout its microstructure. In other words, the composition macroscopically comprises an amorphous alloy that is distributed substantially uniformly throughout the composition. In an alternative embodiment, the composition can be of a composite material having an amorphous phase with a non-amorphous phase therein. This non-amorphous phase can be a single crystal or multiple crystals. The crystals can be in the form of particulates of any shape, such as spherical, oval, wire, rod, sheet, flake, or irregular shape. In one embodiment, the crystals can have a dendritic morphology. For example, an at least partially amorphous composite composition may have a crystalline phase in the form of dendrites dispersed in an amorphous phase matrix, and this dispersion may be uniform or non-uniform. In one embodiment, the amorphous phase and the crystalline phase can have the same chemical composition or different chemical compositions, and the phases can have substantially the same chemical composition. In another embodiment, the crystalline phase can be more ductile than the BMG phase.

  The methods described herein may be applicable to any type of amorphous alloy. Similarly, the amorphous alloy described herein as a component of the composition or article can be of any type. The amorphous alloy may include elements of Zr, Hf, Ti, Cu, Ni, Pt, Pd, Fe, Mg, Au, La, Ag, Al, Mo, Nb, Be, or combinations thereof. That is, the alloy may include any combination of these elements in its chemical formula or chemical composition. These elements can be present in various weight or volume percentages. For example, an iron “base” alloy can refer to an alloy having a non-negligible weight percentage of iron present therein, the weight percentage being at least about 40% by weight, for example, at least about 40% by weight. It may be at least about 20%, such as 50%, such as at least about 60%, such as at least about 80%. Alternatively, in one embodiment, the percentages described above can be volume percentages instead of weight percentages. Thus, the amorphous alloy can be a zirconium base, a titanium base, a platinum base, a palladium base, a gold base, a silver base, a copper base, an iron base, a nickel base, an aluminum base, a molybdenum base, and the like. The alloy may also not include any of the above-described elements to suit a particular purpose. For example, in some embodiments, the alloy, or a composition comprising the alloy, can be substantially free of nickel, aluminum, titanium, beryllium, or combinations thereof. In one embodiment, the alloy or composite material does not include any nickel, aluminum, titanium, beryllium, or combinations thereof.

For example, the amorphous alloy may have the formula (Zr, Ti) _a (Ni, Cu, Fe) _b (Be, A1, Si, B) _c , where a, b, and c are Each represents a weight percentage or an atomic percentage. In one embodiment, in atomic percent, a is in the range of 30-75, b is in the range of 5-60, and c is in the range of 0-50. Alternatively, the amorphous alloy can have the formula (Zr, Ti) _a (Ni, Cu) _b (Be) _c , where a, b, and c are weight percentages or atomic percentages, respectively. Represent. In one embodiment, in atomic percent, a is in the range of 40-75, b is in the range of 5-50, and c is in the range of 5-50. The alloy may also have the formula (Zr, Ti) _a (Ni, Cu) _b (Be) _c , where a, b, and c represent weight percentage or atomic percentage, respectively. In one embodiment, in atomic percent, a is in the range of 45-65, b is in the range of 7.5-35, and c is in the range of 10-37.5. Alternatively, the alloy can also have the formula (Zr) _a (Nb, Ti) _b (Ni, Cu) _c (A1) _d , where a, b, c, and d are each weight Represents a percentage or atomic percentage. In one embodiment, in atomic percent, a is in the range of 45-65, b is in the range of 0-10, c is in the range of 20-40, and d is in the range of 7.5-15. . One exemplary embodiment of the above alloy system is Zr-Ti-Ni- of the trade name Vitreloy (TM), such as Vitreloy-1 and Vitreloy-101, as manufactured by Liquidmetal Technologies (CA, USA). It is a Cu-Be based amorphous alloy. Some examples of various systems of amorphous alloys are listed in Table 1.

These amorphous alloys can also be iron alloys, such as (Fe, Ni, Co) based alloys. Examples of such compositions are US Pat. Nos. 6,325,868, 5,288,344, 5,368,659, 5,618,359, and , 735, 975 (Inoue et al.), Appl. Phys. Lett. , Volume 71, p 464 (1997) (Shen et al.), Mater. Trans. , JIM, Volume 42, p 2136 (2001), and Japanese Patent Application No. 200126277 (publication number 2001303218A). One exemplary composition is Fe ₇₂ A1 ₅ Ga ₂ P _ll C ₆ B ₄ . Another example is Fe ₇₂ A1 ₇ Zr ₁₀ Mo ₅ W ₂ B ₁₅ . Another iron-based alloy system that can be used for coating herein is disclosed in U.S. Patent Application Publication No. 2010/0084052, the amorphous metal having a composition described in parentheses, for example. Of manganese (1 to 3 atomic%), yttrium (0.1 to 10 atomic%), and silicon (0.3 to 3.1 atomic%), and the composition described in parentheses The following elements in the specified range: Chromium (15-20 atom%), Molybdenum (2-15 atom%) Tungsten (1-3 atom%), Boron (5-16 atom%), Carbon (3-16 atom%) And the balance iron.

The amorphous alloy system described above may further include additional elements, such as additional transition metal elements including Nb, Cr, V, and Co. These additive elements may be present at about 30 wt% or less, such as about 20 wt% or less, such as about 10 wt% or less, such as about 5 wt%. In one embodiment, the optional additive element is at least one of cobalt, manganese, zirconium, tantalum, niobium, tungsten, yttrium, titanium, vanadium, and hafnium, forming carbides and wear resistant. Further improve the properties and corrosion resistance. Further optional elements may include phosphorus, germanium, and arsenic, up to a total of about 2%, preferably less than 1%, to lower the melting point. Other minor impurities should be less than about 2%, preferably less than 0.5%.

  In some embodiments, a composition having an amorphous alloy can include a small amount of impurities. By intentionally adding impurity elements, the properties of the composition, such as improved mechanical properties (eg, hardness, strength, fracture mechanism, etc.) and / or improved corrosion resistance can be modified. Alternatively, the impurities may be present as inevitable incidental impurities, such as those obtained as processing and manufacturing by-products. This impurity is about 10% or less, such as about 5% or less, such as about 2% or less, such as about 1% or less, such as about 0.5% or less, such as about 0.1% or less. can do. In some embodiments, these percentages can be volume percentages instead of weight percentages. In one embodiment, the alloy sample / composition consists essentially of an amorphous alloy (having only a small amount of incidental impurities). In another embodiment, the composition comprises an amorphous alloy (having no observable trace impurities).

  In one embodiment, the final part exceeded the critical cast thickness of the bulk solidified amorphous alloy.

  In embodiments herein, superplastic forming is possible due to the presence of a supercooled liquid region in which the bulk solidified amorphous alloy can exist as a high viscosity liquid. Large plastic deformation can be obtained. The ability to undergo significant plastic deformation within the supercooled liquid region may be used for the molding and / or cutting process. In contrast to solids, this liquid bulk solidified alloy deforms locally, which greatly reduces the energy required for cutting and forming. The ease of cutting and forming varies with the temperature of the alloy, mold and cutting tool. As the temperature increases, the viscosity decreases, resulting in easier cutting and molding.

  Embodiments herein can utilize a thermoplastic molding process using amorphous alloys, for example, performed at Tg-Tx. As used herein, Tx and Tg are determined from standard DSC measurements at typical heating rates (eg, 20 ° C./min) as the temperature of onset of crystallization and the temperature of onset of glass transition. .

  The amorphous alloy component can have a critical casting thickness, and the final part can have a thickness greater than its critical casting thickness. Furthermore, the time and temperature of the heating and shaping operations are selected so that the elastic strain limit of the amorphous alloy can be substantially maintained above 1.0%, preferably above 1.5%. In the context of embodiments herein, the temperature near the glass transition means that the molding temperature can be below the glass transition temperature, near the glass transition temperature or glass transition temperature, and above the glass transition temperature. The temperature is preferably lower than the crystallization temperature Tx. The cooling step is performed at a rate similar to the heating rate in the heating step, preferably at a rate exceeding the heating rate in the heating step. The cooling step is also preferably accomplished while the forming and shaping loads are still maintained.

  Embodiments of the injection molding system 10 described above can be used in manufacturing equipment and / or processes that include the use of BMG (or amorphous alloy). Because of the superior properties of BMG, BMG can produce bulk amorphous alloy components in a variety of articles, devices and parts. One such type of device is an electronic device.

Electronic Device The embodiments described herein can be valuable in creating an electronic device using BMG. As used herein, an electronic device can refer to any electronic device known in the art. For example, the electronic device can be any communication device such as a phone such as a mobile phone and a landline phone, or a smartphone including, for example, iPhone ™, and an e-mail sending / receiving device. The electronic device can be part of a display, such as a digital display, TV monitor, electronic book reader, portable web browser (eg, iPad ™), and computer monitor. The electronic device may also be an entertainment device, including music players such as portable DVD players, conventional DVD players, Blu-ray disc players, video game consoles, portable music players (eg, iPod ™), and the like. it can. The electronic device can also be part of a device that provides control (eg, Apple TV ™), such as controlling image, video, audio streaming, or remote control for the electronic device It can be a device. This electronic device may be part of a computer accessory such as a computer or hard disk drive tower enclosure or casing, laptop enclosure, laptop keyboard, laptop trackpad, desktop keyboard, mouse, and speakers. it can. This article can also be applied to devices such as watches or watches.

  Although the principles of the present disclosure are clarified in the exemplary embodiments described above, various modifications may be made to the structures, arrangements, proportions, elements, materials, and components used to implement the present disclosure. It will be apparent to those skilled in the art to obtain.

  It will be appreciated that the above-described and various other features and functions, or alternatives thereof, may be suitably combined with many other different systems / devices or applications. Various alternatives, changes, variations, or improvements in these that are not currently anticipated or anticipated may subsequently be made by those skilled in the art and are intended to be included within the scope of the following claims .

Claims (8)

An injection molding system,
A material input device for charging the system with unmelted material;
A melting zone configured to melt the unmelted material received therein into a molten material and to hold the molten material therein ;
An induction source configured to melt the unmelted material and disposed in the melting zone;
A plunger rod configured to emit the molten material into the mold from the melt zone,
And at least one vacuum source configured to depressurize at least the melting zone and the mold,
The mold is disposed downstream from the induction source downstream of the melting zone;
The plunger rod, the melting zone, and the mold are provided inline and on a horizontal axis, whereby the plunger rod moves inline along the horizontal direction through the melting zone, and the molten material is An injection molding system that moves horizontally into the mold at a location spaced from the induction source to form a molded article comprising a bulk amorphous alloy.   The melting zone includes a container having a body for receiving the unmelted material such that the body receives the plunger rod horizontally through the interior for moving the molten material. The system of claim 1, configured.   The system of claim 2, wherein the container includes one or more temperature control tubes configured to flow liquid therein to adjust the temperature of the container.   The system of claim 1, further comprising a transfer sleeve configured to receive the molten material through an interior between the melting zone and the mold. An injection molding system,
A container containing a configured body so as to hold the material to be melted receptor, melting the pre-SL material internally, and the molten material therein,
An induction source configured to melt the material to be melted and disposed adjacent to the container;
A plunger rod configured to move the molten material from the container,
A transfer sleeve in communication with the container;
A mold for forming a molded article comprising a bulk amorphous alloy;
And at least one vacuum source configured to depressurize at least the container and the mold, the mold being disposed downstream of the transfer sleeve and spaced from the induction source,
The plunger rod, the container, the transfer sleeve, and the mold are provided on an in-line and horizontal axis so that the plunger rod moves horizontally through the container and removes the molten material from the horizontal. An injection molding system that moves inline along the direction into the transfer sleeve and inline into the mold.   The system of claim 5, wherein the container includes one or more temperature control tubes configured to flow liquid therein to adjust the temperature of the container. An injection molding system,
A charging port for providing an amorphous alloy material to be melted;
A temperature controlled container including a body for holding the amorphous alloy material therein, wherein the container is configured to flow a liquid therein to adjust the temperature of the container A temperature-controlled container including the above-mentioned temperature control tube;
An induction source disposed adjacent to the temperature controlled container to heat the container and melt the amorphous alloy material held therein;
Located downstream of the melting zone and spaced from the induction source, configured to receive the molten amorphous alloy through an inlet, and to form the molten amorphous alloy material under reduced pressure A vacuum mold composed of
A plunger rod for injecting the molten amorphous alloy material from the body of the temperature controlled container into the vacuum mold to form a molded article comprising a bulk amorphous alloy;
At least one vacuum source configured to depressurize at least the temperature-controlled container and the mold;
The temperature-controlled container, the inlet of the vacuum mold, and the plunger rod are provided on an in-line and horizontal axis so that the plunger rod is horizontal through the body of the temperature-controlled container. Moving inline along the direction, and injecting the molten material from the temperature-controlled container in the horizontal direction into the vacuum mold at a position spaced from the induction source via the inlet ;
The container holds the molten amorphous alloy material inside the container until the molten amorphous alloy material is injected from the main body into the vacuum mold.   The system of claim 7, further comprising a transfer sleeve configured to receive the molten material through an interior and between the temperature controlled container and the mold.

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