Systems and methods for fabricating objects from bulk metallic glass matrix composites using primary crystallization

Abstract

Systems and methods in accordance with embodiments of the invention implement bulk metallic glass matrix composites in the fabrication of objects. In one embodiment, a method of fabricating an object including a bulk metallic glass matrix composite includes: forming a bulk metallic glass matrix composite composition into the shape of the object to be fabricated; and developing the bulk metallic glass matrix composite composition to include non-equilibrium inclusions that are softer than the surrounding matrix as measured by one of: the shear modulus, the elastic limit, and the hardness; where the bulk metallic glass matrix composite composition is such that the extent of the presence of the inclusions can be made to vary.

What is claimed is: 
     
         1 . A method of fabricating an object including a bulk metallic glass matrix composite comprising:
 forming a bulk metallic glass matrix composite composition into the shape of the object to be fabricated; and   developing the bulk metallic glass matrix composite composition to include non-equilibrium inclusions that are softer than the surrounding matrix as measured by one of: the shear modulus, the elastic limit, and the hardness;   wherein the bulk metallic glass matrix composite composition is such that the extent of the presence of the inclusions can be made to vary.   
     
     
         2 . The method of  claim 1 , wherein the forming of the bulk metallic glass matrix composite composition is achieved using one of: a thermoplastic forming technique and a casting technique. 
     
     
         3 . The method of  claim 2  wherein the forming of the bulk metallic glass matrix composite composition is achieved using one of: die casting, injection casting, rapid capacitive discharge forming, powder injection metallurgy, and investment casting. 
     
     
         4 . The method of  claim 2 , wherein the non-equilibrium inclusions are developed such that they impart desired materials properties in the object to be fabricated. 
     
     
         5 . The method of  claim 4 , wherein developing the bulk metallic glass matrix composite composition to include non-equilibrium inclusions comprises subjecting the bulk metallic glass matrix composite composition to an appropriate cooling rate. 
     
     
         6 . The method of  claim 5 , wherein subjecting the bulk metallic glass matrix composite composition to an appropriate cooling rate develops non-equilibrium inclusions in a first region of the object to be fabricated, but not in a second region of the object to be fabricated. 
     
     
         7 . The method of  claim 6 , wherein the second region of the object to be fabricated is locally heat treated to develop non-equilibrium inclusions. 
     
     
         8 . The method of  claim 4 , wherein developing the bulk metallic glass matrix composite comprises heat treating the formed bulk metallic glass matrix composite composition. 
     
     
         9 . The method of  claim 8 , wherein the heat treating is annealing. 
     
     
         10 . The method of  claim 8 , wherein the heat treating is localized to regions of the formed bulk metallic glass matrix composite composition. 
     
     
         11 . The method of  claim 4 , wherein the extent of the presence of the inclusions can be made to vary by thermal processing. 
     
     
         12 . The method of  claim 4 , wherein the crystalline structures that are developed undergo martensitic transformation when subjected to strain beyond a predetermined threshold. 
     
     
         13 . The method of  claim 4 , wherein the bulk metallic glass matrix composite composition does not include beryllium. 
     
     
         14 . The method of  claim 4 , wherein the bulk metallic glass matrix composite composition is Zr 48 Cu 47.5 Al 4 CO 0.5 . 
     
     
         15 . The method of  claim 4 , wherein the non-equilibrium inclusions are B2 phase inclusions. 
     
     
         16 . The method of  claim 4 , wherein, the bulk metallic glass matrix composite composition is Cu 47.5 Zr 47.5 Al 5 . 
     
     
         17 . The method of  claim 4 , wherein the bulk metallic glass matrix composite composition is one of: a CuZr-based composition, a TiCu-based composition, an NiTi-based composition, a CuZnAl-based composition, an FeNi-based composition, NiP-based composition, FeP-based composition, a FeNiCoAlTaB-based composition, a ZrTi-based composition, a ZrNb-based composition, an NiNb-based composition, a ZrV-based composition, a TiNB-based composition, a ZrTiTa-based composition, TiV-based composition, TiTa-based composition, a ZrTa-based composition, and a ZrCu based composition. 
     
     
         18 . The method of  claim 4 , wherein the non-equilibrium inclusions are spherical. 
     
     
         19 . The method of  claim 4 , wherein the object to be formed is a golf head casing. 
     
     
         20 . The method of  claim 19 , wherein a striking surface of the golf head casing is locally heat treated to develop the non-equilibrium inclusions.