Methods and Systems for Fabricating Layers of Metallic Glass-Based Materials

Abstract

Systems and methods of fabricating layers of metallic glass are described. Many embodiments provide conduction quenching processes to form a metallic glass coating. In many embodiments, the systems and methods comprise applying a metallic glass forming material to form a layer on at least a portion of an object, heating up the layer of metallic glass forming alloy, and cooling the layer of metallic glass-based material to form a layer of solid phase metallic glass.

What is claimed is: 
     
         1 . A method of fabricating metallic glass comprising:
 applying at least one layer of metallic glass forming alloy to at least a portion of an object;   heating the at least one layer of metallic glass forming alloy to at least above the melting temperature of the metallic glass forming alloy; and   cooling the at least one melted layer of liquid phase metallic glass to form a layer of solid phase metallic glass on the at least a portion of the object;   wherein the cooling process is selected from the group consisting of: conduction quenching, gas quenching, dipping in water, dipping in oil, and dipping in molten tin.   
     
     
         2 . The method of  claim 1 , wherein the at least one layer of metallic glass forming alloy comprises at least one element selected from the group consisting of: Zr, Ti, Cu, Al, Nb, Pt, Pd, Au, Ni, Fe, Mg, Ce, La, Be, P, C, and B. 
     
     
         3 . The method of  claim 1 , wherein the object is made of a material with a higher melting temperature than the melting temperature of the metallic glass forming alloy. 
     
     
         4 . The method of  claim 1 , wherein the at least one layer of metallic glass forming alloy is in a form selected from the group consisting of: powder, particle, granule, chunk, foil, ribbon, and sheet. 
     
     
         5 . The method of  claim 4 , wherein the at least one layer of metallic glass forming alloy is cut to match the shape of the at least a portion of the object before applying. 
     
     
         6 . The method of  claim 1 , wherein the at least one layer of metallic glass forming alloy is heated to at least 150° C. above the melting temperature of the metallic glass forming alloy. 
     
     
         7 . The method of  claim 1 , wherein the heating is applied by a heating source selected from the group consisting of an induction heating coil, a resistive furnace, a heating lamp, a laser, an electron beam, a combustion flame, an electrical spark, and a microwave plasma. 
     
     
         8 . The method of  claim 1 , wherein the heating takes place on a heating platform comprising a heating block. 
     
     
         9 . The method of  claim 8 , wherein the heating block comprises a material selected from the group consisting of copper, brass, steel and stainless steel. 
     
     
         10 . The method of  claim 8 , wherein the conduction quenching is applied by at least one conduction quenching block, and the at least one conduction quenching block is aligned with the heating block in the center. 
     
     
         11 . The method of  claim 8 , wherein the conduction quenching is applied by two conduction quenching blocks; wherein a first conduction quenching block is above the heating block and not touching, and a second conduction quenching block is below the heating block; wherein the two conduction quenching blocks and the heating block are aligned in the center. 
     
     
         12 . The method of  claim 1 , wherein the cooling takes place immediately after the heating is complete. 
     
     
         13 . The method of  claim 1 , wherein the heating and cooling take place in vacuum. 
     
     
         14 . The method of  claim 1 , wherein the layer of solid phase metallic glass has a uniform thickness throughout the layer, and the thickness ranges from about 1 micron to about 1 millimeter. 
     
     
         15 . The method of  claim 1 , wherein the layer of solid phase metallic glass has a surface roughness ranging from about 0.020 micron Ra to about 250 micron Ra. 
     
     
         16 . The method of  claim 1 , wherein the layer of solid phase metallic glass has a microstructure selected from the group consisting of: fully amorphous, amorphous and crystalline, and fully crystalline. 
     
     
         17 . A system for fabricating metallic glass comprising:
 at least one heating platform;   at least one sample holder on the at least one heating platform; and   at least one cooling block above the at least one heating platform;   wherein the at least one cooling block is not touching the at least one heating platform;   wherein the at least one heating platform, the at least one sample holder, and the at least one cooling block are aligned in the center.   
     
     
         18 . The system of  claim 17 , further comprising a second cooling block below the at least one heating platform, wherein the second cooling block is in contact with the at least one heating platform. 
     
     
         19 . The system of  claim 17 , wherein the at least one heating platform comprises a heating block comprising a material selected from the group consisting of: copper, brass, and steel. 
     
     
         20 . The system of  claim 17 , wherein the at least one cooling block comprises a material selected from the group consisting of: copper, brass, and steel. 
     
     
         21 . The system of  claim 18 , wherein the second cooling block is cooled by water. 
     
     
         22 . The system of  claim 17 , wherein the at least one heating platform comprising a heating source selected from the group consisting of an induction heating coil, a resistive furnace, a heating lamp, a laser, an electron beam, a combustion flame, an electrical spark, and a microwave plasma.