Ultrasonic Cladding of Amorphous Metal Foils Without Crystallization
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Solution Overview
Problem
Amorphous metal alloys are limited in engineering applications due to low fracture toughness, difficulty in joining with other materials, and scale-up challenges, with existing cladding methods being labor-intensive and difficult to achieve desired specifications, and current bonding methods, such as mechanical interlocking, having limitations in operating temperature and strength.
Innovation Solution
Ultrasonic Additive Manufacturing (UAM) is used to metallurgically bond amorphous metal foils to substrates through plastic deformation, creating a strong, micron-sized bond zone with minimal crystallinity, allowing for the creation of ductile and fracture-resistant bulk metallic glass composites with enhanced properties like high corrosion resistance and strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional cladding methods (roll bonding, co-extrusion, weld overlay, laser cladding) are used to manufacture cladded surfaces, then various materials can be joined, but the process becomes labor-intensive and time-consuming with difficulty achieving desired specifications
Solution Approach 1:
The invention changes the fundamental parameters of the cladding process by using ultrasonic additive manufacturing instead of traditional methods. This involves using ultrasonic vibration energy to create solid-state bonding at lower temperatures and pressures, with layer-by-layer deposition controlled by digital models, thereby improving both manufacturing efficiency and precision
Solution Approach 2:
The invention replaces traditional thermal-based cladding methods (weld overlay, laser cladding) with an ultrasonic mechanical vibration-based system. The ultrasonic horn imparts high-frequency vibrations that facilitate metallurgical bonding without excessive heat input, enabling precise control over the cladding process
2Strength
If mechanical interlocking is used to bond BMG droplets to substrate, then bonding can be achieved, but operating temperature and strength are limited
Solution Approach 1:
The invention utilizes phase transition concepts by controlling the thermal history of the BMG material during ultrasonic additive manufacturing. The process maintains temperatures below the glass transition temperature to preserve the amorphous phase, while ultrasonic energy provides the necessary bonding mechanism, achieving strong metallurgical bonds without compromising the BMG's temperature resistance
Solution Approach 2:
The invention creates a composite structure where BMG materials are metallurgically bonded to substrates through ultrasonic additive manufacturing. This composite approach combines the high strength and wear resistance of BMG with the ductility and toughness of substrate materials, achieving superior overall performance including enhanced bond strength and operating temperature capability
3Strength
If amorphous metal alloys are used, then high hardness and low melting point are achieved, but fracture toughness and joining difficulty increase
Solution Approach 1:
The invention creates laminate composites by alternating layers of amorphous metal alloys and ductile metal layers during ultrasonic additive manufacturing. This composite structure combines the high hardness and wear resistance of amorphous metals with the high ductility and fracture toughness of crystalline metals, achieving a balance of properties that overcomes the limitations of monolithic amorphous metals
Solution Approach 2:
The invention applies different material properties to different locations within the structure. Amorphous metal layers provide local high hardness and wear resistance where needed, while ductile metal layers provide local toughness and fracture resistance, creating a functionally graded structure with optimized local properties
4Temperature
If UAM is used to create dissimilar metal structures, then processing temperature is reduced and high temperature chemistry is suppressed, but achieving strong metallurgical bonds between amorphous and crystalline metals becomes challenging
Solution Approach 1:
The invention uses ultrasonic mechanical vibration as the primary bonding mechanism. The ultrasonic horn imparts high-frequency vibrations (typically 20-100 kHz) to the interface between layers, creating intense localized mechanical action that breaks oxide films, promotes intimate contact, and facilitates metallurgical bonding at reduced temperatures, achieving strong bonds between dissimilar metals including amorphous and crystalline materials
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
The UAM process enables the production of cladded composites with improved ductility and fracture toughness, maintaining amorphous microstructure without thermal stress or crystallinity, achieving strength up to 2,000-3,500 MPa and superior corrosion and wear resistance, suitable for high-temperature applications.
Implementation Method 1
Ultrasonic Additive Manufacturing (UAM) is used to metallurgically bond amorphous metal foils to substrates through plastic deformation
Implementation Method 2
Ultrasonic Additive Manufacturing (UAM) is used to metallurgically bond amorphous metal foils to substrates through plastic deformation
Data Source
AI summary
An embodiment relates to an ultrasonic additive manufacturing process, comprising joining a foil comprising a bulk metallic glass to a substrate; and forming a cladded composite comprising the foil and the substrate; wherein a thickness of the cladded composite is greater than a critical casting thickness of the bulk metallic glass, wherein the cladded composite comprises a cladding layer of the bulk metallic glass on the substrate and the bulk metallic glass comprises approximately 0% crystallinity, approximately 0% porosity, less than 50 MPa thermal stress, approximately 0% distortion, approximately 0 inch heat affected zone, approximately 0% dilution, and a strength of about 2,000-3,500 MPa.