Methods for constructing parts with improved properties using metallic glass alloys

Abstract

Described herein are methods of constructing a part having improved properties using metallic glass alloys, layer by layer. In accordance with certain aspects, a layer of metallic glass-forming powder is deposited to selected positions and then fused to a surface layer (i.e. layer below) by suitable methods such as laser heating or electron beam heating. The deposition and fusing are then repeated as need to construct the part, layer by layer. In certain embodiments, one or more sections or layers of non-metallic glass-forming material can be included as needed to form a composite final part. In certain aspects, the metallic glass-forming powder may be crystalized during depositing and fusing, or may be recrystallized during subsequent processing to provide selectively crystalized sections or layers, e.g., to impart desired functionality. In other aspects, non-metallic glass-forming materials may be deposited and fused at selected positions, e.g., to provide selective shear banding to impart improved ductile properties and plasticity. In yet other aspects, the metallic glass-forming powder or metallic glass material and non-metallic glass-forming material are deposited and fused to form a foam-like, bellow or similar structure, which is able to crumple under high stress to absorb energy under impact.