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Acta Metall Sin  2021, Vol. 57 Issue (4): 515-528    DOI: 10.11900/0412.1961.2020.00414
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New Development of Research on Casting of Bulk Amorphous Alloys
LIU Riping(), MA Mingzhen(), ZHANG Xinyu
State Key Laboratory of Metastable Materials Preparation Technology and Science, Yanshan University, Qinhuangdao 066004, China
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LIU Riping, MA Mingzhen, ZHANG Xinyu. New Development of Research on Casting of Bulk Amorphous Alloys. Acta Metall Sin, 2021, 57(4): 515-528.

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Abstract  

Bulk amorphous alloys possess a metastable structure, which is difficult to process and manufacture into components or parts by conventional forging or welding. Instead, components or parts from bulk amorphous alloys can be fabricated by vacuum casting with the fluidity of bulk amorphous-alloy melts. Based on the casting forming of bulk amorphous alloys, this paper briefly introduces the fluidity and filling ability of bulk amorphous-alloy melts. In addition, the technical methods and applications of vacuum die casting, vacuum suction casting, gravity casting in a water-cooled copper crucible, and phase-change refrigeration casting are also mentioned. The theoretical problems and technical bottlenecks to be resolved in the forming process of bulk amorphous alloys are then discussed. Finally, the engineering application prospects of bulk amorphous alloys are suggested.
Key words:  bulk amorphous alloy      fluidity      casting forming      vacuum die casting      vacuum suction casting     
Received:  20 October 2020     
ZTFLH:  TG139  
Fund: National Natural Science Foundation of China(52071278);National Key Research and Development Program of China(2018YFA0703603)
About author:  MA Mingzhen, professor, Tel: (0335)8074723, E-mail: mz550509@ysu.edu.cn
LIU Riping, professor, Tel: (0335)8074723, E-mail: riping@ysu.edu.cn
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Riping LIU
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Xinyu ZHANG

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https://www.ams.org.cn/EN/10.11900/0412.1961.2020.00414     OR     https://www.ams.org.cn/EN/Y2021/V57/I4/515

Fig.1  Schematic of fluidity test apparatus and photograph of water-cooled mold[38] (p0—pressure in the suction tube, p1—pressure on the liquid surface)
Fig.2  Influence of casting temperatures and pressures on fluidity length at radii of 2.0 mm (a), 2.5 mm (b), and 3.0 mm (c); influence of casting pressures and radii on fluidity length at 1123 K (d); and longitudinal section of fluidity sample of 6 mm diameter under different casting conditions (e) (I: 1273 K, 0.025 MPa; II: 1173 K, 0.025 MPa; III: 1123 K, 0.020 MPa. Δp—pressure difference between two ends of circular pipe, r—radius of circular tube)[38]
Temperature / KΔp / MPa
0.0200.0250.0300.035
1073●●◘◘
1123●◘◘◘
1173◘◘◘◘
1223◘☆☆☆
1273◘☆☆☆
Table 1  Quality of fluidity test sample of 6 mm in diameter[38]
Fig.3  Schematic illustration of the high pressure die casting setup (a), 3D model of the die (b), and completed dies made from heat resistant steel and a copper alloy (c, d)[40]
Fig.4  SEM images of the key cast at 1353 K[40]
Fig.5  Illustration of the entire process vacuum high pressure die casting (EPV-HPDC) equipment and operating mode[41]
Fig.6  Image of Zr55Cu30Ni5Al10 bulk metallic glasses (BMGs) smartphone frame and the corresponding runner system (a), and the 3D distribution of the porosity in the smartphone frame (b) (A, B, C, and D denote different regions)[41]
Fig.7  BMG parts with various shapes and used in different fields[41]
Fig.8  Prototyping bulk metallic glass flexsplines, and DSC curves and XRD spectra[46]
Fig.9  Commercial casting of BMG flexsplines[46]
Fig.10  Zirconium-based bulk amorphous alloy castings cast by water-cooled copper crucible melting metal copper mold
Casting moldingCast amorphous alloyAdvantageDisadvantage
technologycasting
Vacuum die castingThin-walled castings such asNear net shape casting, fastLimited casting thickness
phone shells, watch shells,speed, high efficiency(0.5-2.0 mm), low process
notebook computeryield, and there are tiny
accessories, etc.pores
Vacuum suction castingSimple cylinder, disk, ring,Stable filling, controllableNot suitable for casting of
or plate-like castingflow state of alloy meltcomplex shaped castings
Water-cooled copperSuitable for casting moldingAmorphous alloy melt does notThe low overheat of the alloy
crucible meltingof various shapes and sizesreact with the crucible, the alloymelt affects the filling ability
copper mold castingcastingsmelt is clean, and it does notand is prone to produce defects
affect the amorphous formingof insufficient pouring
ability
Ceramic or graphiteSuitable for casting moldingAlloy melt with a largeThe alloy melt reacts with the
crucible melting copperof various shapes and sizescontrollable range of overheat,crucible to reduce the amorphous
mold castingcastingsgood filling ability, easy toforming ability, and it is only
obtain complete castingssuitable for alloy systems with
strong forming ability
Phase transformationSuitable for casting moldingControllable cooling rateAdditional cooling medium is
refrigeration castingof various shapes and sizesrequired and is difficult to
castingsoperate
Table 2  Applicability, advantages and disadvantages of different casting molding technologies
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