Flexible Bulk Metallic Glass Structures for Complex Thin-Wall Forming
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Solution Overview
Problem
Conventional methods for manufacturing flexible metal elements, such as bellows and hoses, are lengthy, difficult, and unsuitable for creating complex high-performance structures due to limitations in metal deformation and design possibilities, especially for achieving complex shapes like high aspect ratios and thin-walled geometries.
Innovation Solution
The use of bulk metallic glasses (BMG) for flexible elements, employing thermoplastic forming techniques to create seamless, compressible, and bendable structures with specific alloys like Zr44Ti11Cu10Ni10Be25, which allows for complex geometries and improved fatigue behavior by minimizing mold-feedstock contact and applying pressure to deform the BMG feedstock.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional metal manufacturing methods (forming, welding, electrodeposition) are used to produce flexible metal elements, then the manufacturing process can be completed using traditional techniques, but the process becomes lengthy, difficult, and unsuitable for creating complex high-performance structures
Solution Approach 1:
The patent applies parameter changes by utilizing the supercooled liquid state of bulk metallic glass (BMG) between its glass transition temperature (Tg) and crystallization temperature (Tx). In this state, the BMG exhibits thermoplastic behavior with low viscosity, enabling it to be deformed into complex shapes through thermoplastic forming. After forming, rapid cooling transforms it into a rigid glassy state, achieving complex geometries that are impossible with conventional metals.
Solution Approach 2:
The patent exploits phase transitions of BMG materials by heating the feedstock above Tg to enter a supercooled liquid state for forming, then rapidly cooling it to transform into a solid glassy state. This phase transition enables the material to flow into complex mold cavities and then lock into the desired shape, resolving the contradiction between ease of manufacture and complex shape capability.
2Strength
If conventional metals are used, then the material provides structural integrity, but the metal is too strong in crystalline state or too fluid in liquid state, lacking an optimum processing condition
Solution Approach 1:
The patent changes the temperature parameter to transform BMG from a rigid glassy state (high strength) to a supercooled liquid state (formable). By controlling temperature between Tg and Tx, the material exhibits optimal processing conditions with low viscosity for forming, then rapidly cooling it restores high strength in the final product, achieving both structural integrity and manufacturing flexibility.
Solution Approach 2:
The patent utilizes phase transitions of BMG to resolve the strength-formability contradiction. In the supercooled liquid state above Tg, the material is formable; upon rapid cooling below Tg, it transforms into a strong glassy state. This phase transition enables the material to be both strong and easily processed, unlike conventional metals that are either strong and difficult to form or fluid and weak.
3Manufacturing precision
If BMG materials are used for flexible elements, then complex geometries with high aspect ratios and thin-walled structures can be formed, but the manufacturing process requires precise temperature control and rapid cooling
Solution Approach 1:
The patent uses phase transitions to achieve high manufacturing precision for complex geometries. By heating BMG feedstock above Tg to create a supercooled liquid state, the material flows to precisely replicate complex mold cavities including high aspect ratios and thin walls. Rapid cooling then locks in the precise geometry, achieving high accuracy despite process complexity.
Solution Approach 2:
The patent applies parameter changes by precisely controlling temperature parameters during forming (maintaining Tg < T < Tx for formability) and then applying rapid cooling. This parameter control enables the material to achieve complex geometries with high precision, as the supercooled liquid state allows complete mold cavity filling while rapid cooling prevents crystallization and maintains dimensional accuracy.
4Reliability
If thermoplastic forming is used to deform BMG feedstock, then seamless structures with improved fatigue behavior can be created, but the process requires heating and rapid cooling cycles
Solution Approach 1:
The patent uses phase transitions to create seamless structures with improved fatigue life. By heating BMG feedstock above Tg and deformable it in the supercooled liquid state, seamless complex geometries are formed without welds or joints that would be fatigue weak points. Rapid cooling then locks in the seamless structure, achieving high reliability despite the heating and cooling cycle time required.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Results in flexible BMG elements with enhanced fatigue life, high flexibility, and corrosion resistance, capable of forming complex shapes and sizes, with improved yield strength and elastic limits compared to traditional metals, and the ability to handle high pressures and various media states.
Implementation Method 1
heating the BMG feedstock to a supercooled liquid state between a glass transition temperature and a crystallization temperature of the BMG feedstock
Implementation Method 2
deforming the BMG feedstock to replicate the shape of the cavity
Implementation Method 3
rapidly cooling the deformed BMG feedstock to transform the deformed BMG feedstock from the supercooled liquid state to a solid glassy state
Data Source
AI summary
Flexible BMG elements and methods for making the flexible BMG elements. The BMG element contains a main body made from a BMG material and may further contain a flange. The main body may contain at least one opening. The main body may be a thin-walled structure that is compressible, extendable, and/or bendable. A surface of the main body may be corrugated with a series of ridges and furrows.