US 11,905,578 B2
Hypoeutectic amorphous metal-based materials for additive manufacturing
Douglas C. Hofmann, Altadena, CA (US); Andre M. Pate, Pasadena, CA (US); and Scott N. Roberts, Altadena, CA (US)
Assigned to California Institute of Technology, Pasadena, CA (US)
Filed by California Institute of Technology, Pasadena, CA (US)
Filed on Nov. 29, 2021, as Appl. No. 17/456,867.
Application 17/456,867 is a continuation of application No. 15/989,083, filed on May 24, 2018, granted, now 11,185,921.
Claims priority of provisional application 62/510,618, filed on May 24, 2017.
Prior Publication US 2022/0212254 A1, Jul. 7, 2022
This patent is subject to a terminal disclaimer.
Int. Cl. B22F 10/10 (2021.01); B33Y 10/00 (2015.01); B33Y 70/00 (2020.01); B33Y 80/00 (2015.01); C22C 16/00 (2006.01); B22F 10/14 (2021.01); B22F 10/18 (2021.01); B22F 10/22 (2021.01); B22F 10/25 (2021.01); B22F 10/28 (2021.01); B22F 10/34 (2021.01)
CPC C22C 16/00 (2013.01) [B22F 10/14 (2021.01); B22F 10/18 (2021.01); B22F 10/22 (2021.01); B22F 10/25 (2021.01); B22F 10/28 (2021.01); B22F 10/34 (2021.01); B33Y 10/00 (2014.12); B33Y 70/00 (2014.12); B33Y 80/00 (2014.12); B22F 2301/205 (2013.01); B22F 2999/00 (2013.01); C22C 2200/02 (2013.01)] 19 Claims
OG exemplary drawing
 
1. A method of producing a layer comprising a bulk amorphous metal material comprising:
identifying a eutectic metallic glass forming alloy characterized by a eutectic critical casting thickness of greater than 1 mm, a eutectic fragility, and a eutectic shear modulus; and comprising:
a first amount of a first component and an additional amount of at least one additional component, wherein
the first component is the most abundant component of the eutectic metallic glass forming alloy, and
a eutectic exists between the first component and the at least one additional component;
forming a hypoeutectic metallic glass forming alloy based on the eutectic metallic glass forming alloy by increasing the amount of the first component at the expense of the sum of the additional amount such that the hypoeutectic metallic glass forming alloy has a critical casting thickness less than the eutectic metallic glass forming alloy, a hypoeutectic fragility and a hypoeutectic shear modulus;
wherein the most abundant component of the hypoeutectic metallic glass forming alloy comprises at least 70 atomic % of the hypoeutectic metallic glass forming alloy;
depositing a molten layer comprising the hypoeutectic metallic glass forming alloy and characterized by a thickness of between 1-250 micrometers; and
allowing the molten layer to cool to form the layer comprising the bulk amorphous metal material having an amorphous fraction of at least 10% by volume.