Amorphous alloy containing feedstock for powder injection molding

Abstract

Provided in one embodiment is a method for producing a composition, the method comprising injecting a feedstock into a mold to produce a workpiece; wherein the feedstock comprises a binder and particulates comprising an amorphous alloy. The feedstock composition is also described.

What is claimed: 
     
         1 . A composition comprising:
 a binder, and   particulates,   
       wherein the particulates comprise an amorphous alloy, and the composition is a feedstock for an injection molding process. 
     
     
         2 . The composition of  claim 1 , further comprising a partially amorphous particulate material, a refractory particulate material, a soft particulate material, a crystalline metal particulate material, a crystalline alloy particulate material, or combinations thereof. 
     
     
         3 . The composition of  claim 1 , further comprising an alloy particulate material comprising Fe, Cu, Co, Ni, Cr, Mo, B, C, Si, W, Mn, Y, Co, Al, Nb, P, Ti, or combinations thereof. 
     
     
         4 . The composition of  claim 1 , wherein the binder comprises a thermoplastic material. 
     
     
         5 . The composition of  claim 1 , wherein the particulates have a spherical or rounded geometry. 
     
     
         6 . The composition of  claim 1 , wherein the particulates have a size of about 1 micron to about 75 microns. 
     
     
         7 . The composition of  claim 1 , wherein the particulates are present in an amount of about 45 vol. % to about 75 vol. % of the composition. 
     
     
         8 . The composition of  claim 1 , wherein the composition is in the form of granules. 
     
     
         9 . A method comprising:
 injecting a feedstock in to a mold to produce a workpiece,   
       wherein the feedstock comprises a binder and particulates comprising an amorphous alloy. 
     
     
         10 . The method of  claim 9 , further comprising removing the binder from the workpiece. 
     
     
         11 . The method of  claim 9 , further comprising sintering the workpiece at a temperature of less than or equal to about 1300° C. 
     
     
         12 . The method of  claim 9 , further comprising producing the feedstock by mixing the binder with the particulates. 
     
     
         13 . The method of  claim 9 , further comprising producing the feedstock in a method comprising:
 forming particulates comprising an amorphous alloy, and   mixing the particulates with a binder,   
       wherein the forming comprises a gas atomization process, and the particulates are spherical. 
     
     
         14 . The method of  claim 9 , further comprising heating the feedstock material prior to injecting the heated feedstock material into the mold. 
     
     
         15 . The method of  claim 9 , wherein the feedstock material is at a temperature of about 100° C. to about 150° C. during the injecting. 
     
     
         16 . An article produced by sintering a workpiece produced by the method of  claim 9 . 
     
     
         17 . The article of  claim 16 , wherein the article is substantially free of binder after the sintering. 
     
     
         18 . The article of  claim 16 , wherein the article is substantially free of the amorphous alloy. 
     
     
         19 . The article of  claim 16 , wherein the article comprises the amorphous alloy. 
     
     
         20 . The article of  claim 16 , wherein the article has a density of at least about 99%. 
     
     
         21 . The article of  claim 16 , wherein the article has a hardness of at least about 500 HV. 
     
     
         22 . The article of  claim 16 , wherein the article is at least one of a medical component, orthodontic component, automotive component, electronic device component, telecommunication device component, aerospace component, firearm component, eyewear component, dental component, sporting good component, pump component, gear component, hinge component, knife or knife edge, cutting edge of a cutting instrument, casing component, and marine component.