Ultrasonic additive manufacturing of cladded amorphous metal products

Abstract

An embodiment relates to an ultrasonic additive manufacturing process, comprising joining a foil comprising a bulk metallic glass to a substrate; and forming a cladded composite comprising the foil and the substrate; wherein a thickness of the cladded composite is greater than a critical casting thickness of the bulk metallic glass, wherein the cladded composite comprises a cladding layer of the bulk metallic glass on the substrate and the bulk metallic glass comprises approximately 0% crystallinity, approximately 0% porosity, less than 50 MPa thermal stress, approximately 0% distortion, approximately 0 inch heat affected zone, approximately 0% dilution, and a strength of about 2,000-3,500 MPa.

What is claimed is: 
     
         1 . An ultrasonic additive manufacturing process, comprising:
 joining a foil comprising a bulk metallic glass to a substrate; and   forming a cladded composite comprising the foil and the substrate;   wherein a thickness of the cladded composite is greater than a critical casting thickness of the bulk metallic glass; and   where an interlayer is between the bulk metallic glass and the substrate.   
     
     
         2 . The ultrasonic additive manufacturing process of  claim 1 , wherein the thickness of the cladded composite is greater than the critical casting thickness of the bulk metallic glass by a factor of at least 15. 
     
     
         3 . The ultrasonic additive manufacturing process of  claim 1 , wherein the ultrasonic additive manufacturing process comprises an amplitude in range of 30 μm to 40 μm and a travel speed in range of 50 inch per minute to 150 inch per minute. 
     
     
         4 . The ultrasonic additive manufacturing process of  claim 1 , wherein the bulk metallic glass and the substrate has an interface; wherein the interface is amorphous. 
     
     
         5 . The ultrasonic additive manufacturing process of  claim 4 , wherein the interface has no Kikuchi pattern. 
     
     
         6 . The ultrasonic additive manufacturing process of  claim 1 , further comprising:
 making the foil;   modifying a surface of the foil;   optionally removing a surface oxide layer of the foil; and   forming a nascent contact of the foil with the substrate.   
     
     
         7 . The ultrasonic additive manufacturing process of  claim 1 , The ultrasonic additive manufacturing process of  claim 1 , wherein the cladded composite comprises a cladding layer of the bulk metallic glass; wherein the bulk metallic glass comprises approximately 0-10% crystallinity, no porosity, less than 50 MPa thermal stress, no heat affected zone, no dilution, and a bond strength of about 2,000-3,500 MPa. 
     
     
         8 . The ultrasonic additive manufacturing process of  claim 7 , wherein the bulk metallic glass comprises Zr, Cu; wherein the substrate comprises steel, aluminum or titanium. 
     
     
         9 . The ultrasonic additive manufacturing process of  claim 8 , wherein the bulk metallic glass further comprises Ni, Al. 
     
     
         10 . The ultrasonic additive manufacturing process of  claim 8 , wherein the cladding layer comprises a foil having a foil thickness of about 20-300 □m and the cladding layer has a thickness of about 0.02 mm to 5 mm. 
     
     
         11 . The ultrasonic additive manufacturing process of  claim 7 , wherein the cladding layer comprises multiple sheets of the foil. 
     
     
         12 . The ultrasonic additive manufacturing process of  claim 7 , wherein the bulk metallic glass comprises Zr, Ti; wherein the substrate comprises steel, aluminum or titanium. 
     
     
         13 . The ultrasonic additive manufacturing process of  claim 12 , wherein the cladding layer comprises a foil having a foil thickness of about 20-300 □m and the cladding layer has a thickness of about 0.02 mm to 5 mm. 
     
     
         14 . The ultrasonic additive manufacturing process of  claim 13 , wherein the cladding layer has a thickness of about 0.1 mm to 0.4 mm. 
     
     
         15 . The ultrasonic additive manufacturing process of  claim 7 , wherein the cladded composite comprises a bond layer between the substrate and the cladding layer. 
     
     
         16 . The ultrasonic additive manufacturing process of  claim 7 , wherein the bulk metallic glass comprises Ni, C; wherein the substrate comprises steel, aluminum or titanium. 
     
     
         17 . The ultrasonic additive manufacturing process of  claim 16 , wherein the cladding layer comprises a foil having a foil thickness of about 20-300 □m and the cladding layer has a thickness of about 0.02 mm to 5 mm. 
     
     
         18 . The ultrasonic additive manufacturing process of  claim 17 , wherein the bulk metallic glass further comprises P or Si. 
     
     
         19 . The ultrasonic additive manufacturing process of  claim 7 , wherein the bulk metallic glass comprises Fe, Co; wherein the substrate comprises steel, aluminum or titanium. 
     
     
         20 . The ultrasonic additive manufacturing process of  claim 19 , wherein the bulk metallic glass further comprises Mo, B, Si, wherein the cladding layer comprises a foil having a foil thickness of about 20-300 □m and the cladding layer has a thickness of about 0.03 mm to 5 mm.