Systems and methods for implementing bulk metallic glass-based macroscale gears

Abstract

Systems and methods in accordance with embodiments of the invention implement bulk metallic glass-based macroscale gears. In one embodiment, a method of fabricating a bulk metallic glass-based macroscale gear, where at least either the thickness of the gear is greater than 3 mm or the diameter of the gear is greater than 9 mm, includes: obtaining design parameters of the gear to be formed; selecting a bulk metallic glass from which the gear will be formed based on the obtained design parameters, where the selected bulk metallic glass is characterized by a resistance to standard modes of wear and a resistance to brittle fracture such that a gear can be formed from the selected bulk metallic glass that accords with the obtained design parameters; and fabricating the gear from the selected bulk metallic glass that accords with the obtained design parameters.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS[0001]The current application claims priority to U.S. Provisional Application No. 61 / 664,620, filed Jun. 26, 2012, the disclosure of which is incorporated herein by reference.STATEMENT OF FEDERAL FUNDING[0002]The invention described herein was made in the performance of work under a NASA contract, and is subject to the provisions of Public Law 96-517 (35 U.S.C. 202) in which the Contractor has elected to retain title.FIELD OF THE INVENTION[0003]The present invention generally relates to bulk metallic glass-based macroscale gears.BACKGROUND[0004]Gears are pervasive engineering components that are commonly used in a variety of actuation mechanisms. For example, gears are typically used to drive automobiles, bicycles, extraterrestrial vehicles, and even watches. Because they experience constant stress during operation, it is desirable that gears be formed of strong and robust materials.[0005]A relatively new class of materials that may be well sui...

AI Technical Summary

Benefits of technology

The patent describes a method for fabricating bulk metallic glass-based macroscale gears that are resistant to standard modes of wear and brittle fracture. The method involves selecting a bulk metallic glass based on the gear's design parameters, which are determined based on the gear's anticipated operational setting. The selected bulk metallic glass is characterized by its resistance to standard modes of wear and its resistance to brittle fracture. The gear can be formed from the selected bulk metallic glass that accords with the obtained design parameters. The method can be used to fabricate gears that are resistant to wear and fracture in various environments, such as below 0°C. The resistance of the bulk metallic glass to standard modes of wear and fracture can be determined based on its fracture toughness and hardness.

Problems solved by technology

Nonetheless, the manufacture of metallic glasses presents challenges that limit their viability as engineering materials.

Indeed, because of this limitation in thickness, metallic glasses were initially limited to applications that involved coatings.

Although metallic glasses can now be formed in dimensions that can allow them to be more useful, the current state of the art has yet to understand BMG materials properties to an extent where ‘macroscale’ gears, for example those of the size that are typically used to drive robotics (e.g., those produced by Maxon Motor), can be efficiently designed.

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