GOALI: Miniature Net-Shape Fabrication Method Using Thermoplastic Forming with Bulk Mettalic Glass

这项与工业联系的资助机会（GOALI）研究项目的目标是开发一种基于大块金属玻璃（bmg）热塑性成型的微型制造方法。BMGS是一种新型的工程材料，具有非常高的强度、弹性和耐腐蚀性，可以像塑料一样在其过冷液体区域热塑性成型。在所提出的制造方法中，将BMG再加热到过冷液体区域，在该区域中，在施加的压力下将其模压成各种形状和尺寸的模具。针对不同的BMG合金，在不同的模具上建立成形压力、加工时间、温度与成形行为之间的关系，以确定最佳的加工条件。为了制造三维零件，制造方法将由成型工艺、热刮法和表面光滑工艺组成，以产生具有超光滑表面光洁度的高精度三维微型零件。为了开发一种经济有效的方法，硅模具必须被替换。由于所需的加工温度不允许使用聚合物模具，因此，可以使用由聚合物热解合成的碳模具。如果成功，本研究结果将为基于大块金属玻璃热塑性成形的新型微型制造方法奠定基础。确定加工参数与成形行为之间的相关性可以作为基于bmg热塑性成形的各种过程的模型描述的基础。在这种方法中，三维微型零件可以以经济有效的方式以最高的精度和表面光滑度生产。这些加工优势和BMG相对于目前使用的微型成形材料的优越性能表明，该方法可能取代目前使用的微型制造方法，成为最具成本效益的工艺。

The goal of this Grant Opportunities for Liaison with Industry (GOALI) research project is to develop a miniature fabrication method based on thermoplastic forming with bulk metallic glasses (BMGs). BMGS are a new class of engineering materials with very high strength, elasticity and corrosion resistance that can be processed like plastics when thermoplasically formed in their supercooled liquid region. Within the proposed fabrication method the BMG is reheated into the supercooled liquid region where it is molded under an applied pressure into molds of various shapes and sizes. The correlation between forming pressure, processing time, temperature and forming behavior will be established for various BMG alloys on different molds to determine the optimal processing conditions. In order to create 3-dimensional parts the fabrication method will be comprised of a molding process, a hot-scraping method, and a surface smoothening process, to yield high precision 3-dimensional miniature parts with an ultra smooth surface finish. To develop a cost effective method silicon molds have to be replaced. Since the required processing temperatures do not permit the use of polymer molds, alternatively, the use of carbon molds which are synthesized by the pyrolyzing of polymers. If successful, the results of this research will lay the foundation of a novel miniature fabrication method based on thermoplastic forming with bulk metallic glass. Determining of the correlation between processing parameters and forming behavior can be used as a foundation of a model description of a wide range of processes based on thermoplastic forming with BMGs. Within this method 3-dimensional miniature parts can be produced with highest precision and surface smoothness in a cost effective manner. These processing advantages and the superior properties of the BMG over currently used miniature forming materials suggest that the proposed method might replace currently used miniature fabrication methods as the most cost effective process.