Systems and methods for shaping sheet materials that include metallic glass-based materials

Abstract

Systems and methods in accordance with embodiments of the invention advantageously shape sheet materials that include metallic glass-based materials. In one embodiment, a method of shaping a sheet of material including a metallic glass-based material includes: heating a metallic glass-based material within a first region within a sheet of material to a temperature greater than the glass transition temperature of the metallic glass-based material; where the sheet of material has a thickness of between 0.1 mm and 10 mm; where at least some portion of the sheet of material does not include metallic glass-based material that is heated above its respective glass transition temperature when the metallic glass-based material within the first region is heated above its respective glass transition temperature; and deforming the metallic glass-based material within the first region while the temperature of the metallic glass-based material within the first region is greater than its respective glass transition temperature.

What claimed is: 
     
         1 . A method of shaping a sheet of material including a metallic glass-based material comprising:
 heating a metallic glass-based material within a first region within a sheet of material to a temperature greater than the glass transition temperature of the metallic glass-based material;
 wherein the sheet of material has a thickness of between approximately 0.1 mm and approximately 10 mm; 
 wherein at least some portion of the sheet of material does not include metallic glass-based material that is heated above its respective glass transition temperature when the metallic glass-based material within the first region is heated above its respective glass transition temperature; and 
   deforming the metallic glass-based material within the first region while the temperature of the metallic glass-based material within the first region is greater than its respective glass transition temperature.   
     
     
         2 . The method of  claim 1 , wherein the sheet of material has a thickness of between approximately 0.1 mm and approximately 3 mm. 
     
     
         3 . The method of  claim 2 , wherein the temperature of the metallic glass-based material within the first region is maintained below its crystallization temperature when it is heated above the glass transition temperature. 
     
     
         4 . The method of  claim 3 , wherein at least a majority of the sheet of material, as measured by volume, does not include metallic glass-based material that is heated above its respective glass transition temperature when the metallic glass-based material within the first region is heated above its respective glass transition temperature. 
     
     
         5 . The method of  claim 3 , wherein heating the metallic glass-based material within the first region is accomplished using one of: induction heating, frictional heating, and a heated fluid. 
     
     
         6 . The method of  claim 3 , wherein deforming the metallic glass-based material within the first region is accomplished by pressing a shaping tool into the sheet of material. 
     
     
         7 . A method of shaping a sheet of material including a metallic glass-based material comprising:
 subjecting a sheet of material comprising a metallic glass-based material to direct contact with a heated fluid so as to raise the temperature of at least some portion of the metallic glass-based material to a temperature that is above its glass transition temperature;
 wherein the sheet of material has a thickness of between approximately 0.1 mm and approximately 10 mm; and 
   deforming the metallic glass-based material that has been heated by the heated fluid to a temperature above its glass transition temperature.   
     
     
         8 . The method of  claim 7 , wherein the sheet of material is between approximately 0.1 mm and 3 mm. 
     
     
         9 . The method of  claim 8 , wherein the metallic glass-based material that is heated above its glass transition temperature because of the heated fluid is maintained at a temperature lower than its crystallization temperature. 
     
     
         10 . The method of  claim 9 , wherein deforming the metallic glass-based material that has been heated by the heated fluid is accomplished by using the heated fluid to deform the sheet of material. 
     
     
         11 . The method of  claim 9 , wherein deforming the metallic glass-based material that has been heated by the heated fluid is accomplished by pressing a shaping tool into the sheet of material as it is supported, at least in part, by the heated fluid. 
     
     
         12 . A method of shaping a sheet of material including a metallic glass-based material comprising:
 moving a surface relative to a sheet of material comprising a metallic glass-based material while the surface and the sheet of material are in direct contact so as to frictionally heat the metallic glass-based material within the sheet of material above its glass transition temperature;
 wherein the sheet of material has a thickness of between approximately 0.1 mm and approximately 10 mm; 
   deforming the metallic glass-based material that has been heated by the frictional heating to a temperature above its glass transition temperature.   
     
     
         13 . The method of  claim 12 , wherein the sheet of material has a thickness of between approximately 0.1 mm and approximately 3 mm. 
     
     
         14 . The method of  claim 13 , wherein the metallic glass-based material that has been heated by the frictional heating is maintained at a temperature lower than its crystallization temperature during the frictional heating. 
     
     
         15 . The method of  claim 14 , wherein moving the surface relative to the sheet of material comprises rotating the surface relative to the sheet of material so as to frictionally heat it. 
     
     
         16 . The method of  claim 15 , wherein deforming the metallic glass-based material is accomplished by pressing the surface into the sheet of material. 
     
     
         17 . The method of  claim 16 , wherein deforming the metallic glass-based material is accomplished by pressing the surface into the sheet of material so that it conforms to the shape of a mold cavity. 
     
     
         18 . The method of  claim 14 , wherein deforming the metallic glass-based material is accomplished by using pressurized gas. 
     
     
         19 . A method of shaping a sheet of material including a metallic glass-based material comprising:
 deforming a metallic glass-based material within a sheet of material at a temperature lower than the glass transition temperature of the metallic glass-based material, the metallic glass-based material having a volume fraction of crystalline phase greater than approximately 30% and a fracture toughness greater than approximately 80 MPa·m 1/2 ;
 wherein the sheet of material has a thickness of between approximately 0.1 mm and approximately 10 mm. 
   
     
     
         20 . The method of  claim 19 , wherein the metallic glass-based material has a volume fraction of crystalline phase of greater than approximately 40% and a fracture toughness greater than approximately 100 MPa·m 1/2 . 
     
     
         21 . The method of  claim 20 , wherein the sheet of material has a thickness that is less than approximately three times the size of the plastic zone radius of the metallic glass-based material. 
     
     
         22 . The method of  claim 21 , wherein the sheet of material has a thickness that is less than approximately one-third the size of the plastic zone radius of the metallic glass-based material. 
     
     
         23 . The method of  claim 20 , wherein the sheet of material has a thickness of between approximately 0.1 mm and approximately 3 mm. 
     
     
         24 . The method of  claim 23 , wherein deforming the metallic glass-based material is accomplished using a pressing tool. 
     
     
         25 . The method of  claim 23 , further comprising:
 removing portions of the sheet of material in a periodic fashion; and   deforming the sheet of material that no longer includes the removed portions so as to form a cellular structure.   
     
     
         26 . The method of  claim 25 , wherein deforming the sheet of material is accomplished using a punch and die. 
     
     
         27 . The method of  claim 23 , wherein the metallic glass-based material is Zr 55.3 Ti 24.9 Nb 10.8 Cu 6.2 Be 2.8 . 
     
     
         28 . A cellular structure comprising a metallic glass-based material having a volume fraction of crystalline phase greater than approximately 30% and a fracture toughness greater than approximately 80 MPa·m 1/2 . 
     
     
         29 . The cellular structure of  claim 28 , wherein the metallic glass-based material has a volume fraction of crystalline phase greater than approximately 40% and a fracture toughness greater than approximately 100 MPa·m 1/2 . 
     
     
         30 . The cellular structure of  claim 28 , wherein the metallic glass-based material is Zr 55.3 Ti 24.9 Nb 10.8 Cu 6.2 Be 2.8 .