Joseph P. Schramm

A damage-tolerant glass

Owing to a lack of microstructure, glassy materials are inherently strong but brittle, and often demonstrate extreme sensitivity to flaws. Accordingly, their macroscopic failure is often not initiated by plastic yielding, and almost always terminated by brittle fracture. Unlike conventional brittle glasses, metallic glasses are generally capable of limited plastic yielding by shear-band sliding in the presence of a flaw, and thus exhibit toughness-strength relationships that lie between those of brittle ceramics and marginally tough metals. Here, a bulk glassy palladium alloy is introduced, demonstrating an unusual capacity for shielding an opening crack accommodated by an extensive shear-band sliding process, which promotes a fracture toughness comparable to those of the toughest materials known. This result demonstrates that the combination of toughness and strength (that is, damage tolerance) accessible to amorphous materials extends beyond the benchmark ranges established by the toughest and strongest materials known, thereby pushing the envelope of damage tolerance accessible to a structural metal.

Beating Crystallization in Glass-Forming Metals by Millisecond Heating and Processing

Resistive heating can be used to rapidly heat a bulk metallic glass without inducing crystallization. The development of metal alloys that form glasses at modest cooling rates has stimulated broad scientific and technological interest. However, intervening crystallization of the liquid in even the most robust bulk metallic glass-formers is orders of magnitude faster than in many common polymers and silicate glass-forming liquids. Crystallization limits experimental studies of the undercooled liquid and hampers efforts to plastically process metallic glasses. We have developed a method to rapidly and uniformly heat a metallic glass at rates of 106 kelvin per second to temperatures spanning the undercooled liquid region. Liquid properties are subsequently measured on millisecond time scales at previously inaccessible temperatures under near-adiabatic conditions. Rapid thermoplastic forming of the undercooled liquid into complex net shapes is implemented under rheological conditions typically used in molding of plastics. By operating in the millisecond regime, we are able to “beat” the intervening crystallization and successfully process even marginal glass-forming alloys with very limited stability against crystallization that are not processable by conventional heating.

Glassy steel optimized for glass-forming ability and toughness

An alloy development strategy coupled with toughness assessments and ultrasonic measurements is implemented to design a series of iron-based glass-forming alloys that demonstrate improved glass-forming ability and toughness. The combination of good glass-forming ability and high toughness demonstrated by the present alloys is uncommon in Fe-based systems, and is attributed to the ability of these compositions to form stable glass configurations associated with low activation barriers for shear flow, which tend to promote plastic flow and give rise to a toughness higher than other known Fe-based bulk-glass-forming systems.

Accessing thermoplastic processing windows in metallic glasses using rapid capacitive discharge

The ability of the rapid-capacitive discharge approach to access optimal viscosity ranges in metallic glasses for thermoplastic processing is explored. Using high-speed thermal imaging, the heating uniformity and stability against crystallization of Zr35Ti30Cu7.5Be27.5 metallic glass heated deeply into the supercooled region is investigated. The method enables homogeneous volumetric heating of bulk samples throughout the entire supercooled liquid region at high rates (~105 K/s) sufficient to bypass crystallization throughout. The crystallization onsets at temperatures in the vicinity of the “crystallization nose” were identified and a Time-Temperature-Transformation diagram is constructed, revealing a “critical heating rate” for the metallic glass of ~1000 K/s. Thermoplastic process windows in the optimal viscosity range of 100–104 Pa·s are identified, being confined between the glass relaxation and the eutectic crystallization transition. Within this process window, near-net forging of a fine precision metallic glass part is demonstrated.

High porosity metallic glass foam : A powder metallurgy route

A powder metallurgy route to the fabrication of metallic glass foam is introduced. The method involves consolidating metallic glass powder blended with blowing agent particulates to produce expandable precursors, capable of yielding foams with porosities as high as 86%. The foams are found to inherit the strength of the parent metallic glass and to be able to deform heavily toward full densification absorbing high amounts of energy.

Metallic-glass-matrix composite structures with benchmark mechanical performance

Metallic-glass-matrix composites demonstrating unusual combination of high strength, high toughness, and excellent processability are utilized to fabricate cellular structures of egg-box topology. Under compressive loading, the egg-box panels are capable of undergoing extensive plastic collapse at very high plateau stresses enabling absorption of large amounts of mechanical energy. In terms of specific mechanical energy absorbed, the present panels far outperform panels of similar topology made of aluminum or fiber-reinforced polymer composites, and even surpass steel structures of highly buckling-resistant topologies, thus emerging among the highest performance structures of any kind.

Compression-compression fatigue of Pd43Ni10Cu27P20 metallic glass foam

Compression-compression fatigue testing of metallic-glass foam is performed. A stress-life curve is constructed, which reveals an endurance limit at a fatigue ratio of about 0.1. The origin of fatigue resistance of this foam is identified to be the tendency of intracellular struts to undergo elastic and reversible buckling, while the fatigue process is understood to advance by anelastic strut buckling leading to localized plasticity (shear banding) and ultimate strut fracture. Curves of peak and valley strain versus number of cycles coupled with plots of hysteresis loops and estimates of energy dissipation at various loading cycles confirm the four stages of foam-fatigue.

Effect of strain rate on the yielding mechanism of amorphous metal foam

Stochastic amorphous Pd_(43)Ni_(10)Cu_(27)P_(20) foams were tested in quasistatic and dynamic loading. The strength/porosity relations show distinct slopes for the two loading conditions, suggesting a strain-rate-induced change in the foam yielding mechanism. The strength/porosity correlation of the dynamic test data along with microscopy assessments support that dynamic foam yielding is dominated by plasticity rather than elastic buckling, the mechanism previously identified to control quasistatic yielding. The strain-rate-induced shift in the foam yielding mechanism is attributed to the rate of loading approaching the rate of sound wave propagation across intracellular membranes, thereby suppressing elastic buckling and promoting plastic yielding.