Metallic mirrors formed from amorphous alloys

Abstract

Metallic mirrors made of bulk-solidifying amorphous alloys, the bulk-solidifying amorphous alloys providing ruggedness, lightweight structure, excellent resistance to chemical and environmental effects, and low-cost manufacturing, and methods of making such metallic mirrors from such bulk-solidifying amorphous alloys are provided.

1 . A metallic mirror comprising at least one reflective surface made of a bulk solidifying amorphous alloy. 
     
     
         2 . The metallic mirror of  claim 1 , wherein the reflective surface is flat. 
     
     
         3 . The metallic mirror of  claim 1 , wherein the reflective surface is curved. 
     
     
         4 . The metallic mirror of  claim 1 , wherein the reflective surface further comprises a deposited dielectric coating layer. 
     
     
         5 . The metallic mirror of  claim 4 , wherein reflective surface further comprises a deposited coating layer comprised of one or more of noble metals. 
     
     
         6 . The metallic mirror of  claim 1 , wherein the amorphous alloy is described by the following molecular formula: (Zr, Ti)a(Ni, Cu, Fe)b(Be, Al, Si, B)c, wherein “a” is in the range of from 30 to 75, “b” is in the range of from 5 to 60, and “c” is in the range of from 0 to 50 in atomic percentages. 
     
     
         7 . The metallic mirror of  claim 1 , wherein the amorphous alloy is described by the following molecular formula: (Zr, Ti)a(Ni, Cu)b(Be)c, wherein “a” is in the range of from 40 to 75, “b” is in the range of from 5 to 50, and “c” is in the range of from 5 to 50 in atomic percentages. 
     
     
         8 . The metallic mirror of  claim 1 , wherein the amorphous alloy can sustain strains up to 1.5% or more without any permanent deformation or breakage. 
     
     
         9 . The metallic mirror of  claim 1 , wherein the amorphous alloy amorphous alloy has a ΔT of 60° C. or greater. 
     
     
         10 . The metallic mirror of  claim 1 , wherein the amorphous alloy has a hardness of 7.5 Gpa and higher. 
     
     
         11 . The metallic mirror of  claim 1 , wherein the reflective surface has a surface smoothness of less than about 3 nm rms. 
     
     
         12 . The metallic mirror of  claim 1 , wherein the reflective surface has a surface smoothness of less than about 1 nm rms. 
     
     
         13 . A metallic mirror system comprising:
 a reflective surface; and   a support structure, wherein at least one of the components the mirror system is made of a bulk solidifying amorphous alloy.   
     
     
         14 . The metallic mirror system of  claim 13 , wherein the reflective surface and the support structure are a single integral structure made of a bulk solidifying amorphous alloy. 
     
     
         15 . The metallic mirror system of  claim 13 , wherein the reflective surface and the support structure comprise separate pieces, each made of a bulk solidifying amorphous alloy, that are joined together into a single integral structure. 
     
     
         16 . The metallic mirror system of  claim 13 , wherein the amorphous alloy is described by the following molecular formula: (Zr, Ti)a(Ni, Cu, Fe)b(Be, Al, Si, B)c, wherein “a” is in the range of from 30 to 75, “b” is in the range of from 5 to 60, and “c” is in the range of from 0 to 50 in atomic percentages. 
     
     
         17 . The metallic mirror system of  claim 13 , wherein the amorphous alloy is described by the following molecular formula: (Zr, Ti)a(Ni, Cu)b(Be)c, wherein “a” is in the range of from 40 to 75, “b” is in the range of from 5 to 50, and “c” is in the range of from 5 to 50 in atomic percentages. 
     
     
         18 . The metallic mirror system of  claim 13 , wherein the amorphous alloy can sustain strains up to 1.5% or more without any permanent deformation or breakage. 
     
     
         19 . The metallic mirror system of  claim 13 , wherein the amorphous alloy has a high fracture toughness of at least 20 ksi-in 0.5 . 
     
     
         20 . The metallic mirror system of  claim 13 , wherein the amorphous alloy amorphous alloy has a ΔT of 60° C. or greater. 
     
     
         21 . The metallic mirror system of  claim 13 , wherein the reflective surface has a surface smoothness of less than about 1 nm rms. 
     
     
         22 . A method of making metallic mirrors of bulk solidifying amorphous alloy, comprising the steps of:
 providing a sheet feedstock of a bulk-solidifying amorphous alloy being in a substantially amorphous state, and having an elastic strain limit of about 1.5% or greater and having a ΔT of 30° C. or greater;   heating the feedstock to around the glass transition temperature of the bulk-solidifying amorphous alloy;   shaping the heated feedstock into a desired mirror shape; and   cooling the formed mirror to temperatures far below the glass transition temperature.   
     
     
         23 . The method of  claim 22 , wherein the ΔT of the amorphous alloy is greater than 90° C. 
     
     
         24 . The method of  claim 22 , wherein the elastic strain limit of the amorphous alloy is substantially preserved during processing to be not less than 1.5%. 
     
     
         25 . The method of  claim 22 , further comprising a finishing process selected from the group consisting of oxide removal, chemical etching, buffing, and polishing. 
     
     
         26 . A method of making metallic mirrors of bulk solidifying amorphous alloy, comprising the steps of:
 providing a homogeneous alloy feedstock of a bulk solidifying amorphous alloy in either an amorphous or non-amorphous state;   heating the feedstock to a casting temperature above the melting temperature of the bulk solidifying amorphous alloy;   introducing the molten alloy into a shape-forming mold; and   quenching the molten alloy to a temperature below the glass transition temperature of the bulk solidifying amorphous alloy.   
     
     
         27 . The method of  claim 26 , wherein the amorphous alloy has a ΔT of greater than 60° C. 
     
     
         28 . The method of  claim 26 , further comprising a finishing process selected from the group consisting of oxide removal, chemical etching, buffing, and polishing.