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Electrochemical micromachining (ECMM) with microtool electrodes is a promising method for microshaping bulk metallic glasses (BMGs) at room temperature. A key challenge is the control of the electrode reactions to impede the disturbing passive layer formation on machined surface regions. In the example case of a Fe-based glassy Fe65.5Cr4Mo4Ga4P12C5B5.5 alloy, it will be demonstrated that by using an aqueous electrolyte based on 0.1 M H2SO4 solution with up to 0.1 M Fe2(SO4)3 addition and by applying ultrashort voltage pulses, complex microstructures can be machined with high precision. Potentiodynamic polarization measurements reveal that the salt addition reduces the charge transfer resistance of the microtool and therefore, the negative bias potential effect. The free corrosion and passive state of the BMG workpiece are affected, but not the transpassive regime. Systematic ECMM studies were conducted to obtain optimum parameters for shaping complex lateral structures with very smooth and well-defined machining areas.

Cast-iron (CI) based bulk amorphous alloy with compositions of Fe75.5−xC6.0Si3.3B5.5P8.7Cu1.0Alx (x = 0, 1 at.%) was synthesized by Cu mold casting. As indicated by increased critical diameters (dmax) for the amorphization, the substitution of Al enhanced the glass-forming ability of the alloy. However, the onset temperature of crystallization (Tx) and the range of supercooled liquid region (ΔTx) of the alloy decreased upon Al addition from 500 °C and 28 °C to 475 °C and 25 °C, respectively. It was revealed that the decreased thermal stability of the amorphous phase is related to the enhanced crystallization tendency to form primary α-Fe phase. Upon the nanocrystallization of primary α-Fe phase the Al-added alloy shows enlarged Ms of 176 emu g−1, still keeping a reasonable small Hc value of 0.086 Oe. The present study revealed that the minor Al addition enhances not only the glass-forming ability, but also the nanocrystallization behavior of the CI based bulk amorphous alloy.

The magnetic Fe–6.5 wt% Si powder was produced by gas atomization and its microstructure was also investigated. The secondary dendritic arm spacing (SDAS) is related to the droplet size, ${\rm{\lambda }} = 0.29 \cdot {D^{0.5}}$, and the numerical solidification model was applied to the system, giving rise to the correlation of microstructure to the solidification process of the droplet. It is found that the solid fraction at the end of recalescence is strongly dependent on the undercooling achieved before nucleation; the chances for the smaller droplets to form the grain-refined microstructures are less than the larger ones. Furthermore, the SDAS is strongly influenced by the cooling rate of post-recalescence solidification, and the relationship can be expressed as follows, ${\rm{\lambda }} = 74.2 \cdot {\left( {\dot T} \right)^{ - 0.347}}$. Then, the growth of the SDAS is driven by the solute diffusion of the interdendritic liquids, leading to a coarsening phenomenon, shown in a cubic root law of local solidification time, ${\rm{\lambda }} = 10.73 \cdot {\left( {{t_f}} \right)^{0.296}}$.

A new technique for micropatterning Fe-based bulk metallic glass surfaces is reported. The transpassive dissolution process is utilized for a defined localized material removal when using a pulsed electrochemical micromachining process. By applying submicrosecond pulses between a work piece and a tool electrode, microholes of high aspect ratio and depth of up to 100 μm can be machined into the bulk glassy Fe65.5Cr4Mo4Ga4P12C5B5.5 alloy. Two potential electrolytes are identified for the machining process. For these electrolytes, different reaction mechanisms are discussed. The possibility of machining more complex structures is demonstrated for the most promising electrolyte, a methanolic H2SO4solution. The impact of the process parameters, pulse length and pulse voltage, on the machining gap and the surface quality of the machined structures is evaluated.

Improved room temperature plasticity was achieved by microalloying Cu in a series of (Fe71Nb6B23)100−xCux (x = 0, 0.25, 0.5, 0.75, and 1) glass matrix alloys with tunable size and volume fraction of precipitates composed of α-Fe and Fe23B6 phases. When ∼10-nm-sized nano-scale precipitates are formed with a size comparable to the shear bandwidth by controlling the added content of Cu, the (Fe71Nb6B23)99.5Cu0.5 alloy exhibits a maximum plastic strain of 4.3 ± 0.8% with pronounced multiple shear banding. A further increase in the size of the precipitates up to micrometer scale results in catastrophic fracture accompanied with irregular cracks, revealing that the fracture mechanism of the different alloys is controlled by the precipitate size.

The compositional dependence of glass formation and thermal and elastic properties was clarified for the ternary La–Al–Co bulk glass-forming system. The existing linear correlation between La concentration and characteristic temperatures, i.e., the glass transition temperature Tg and the onset temperature of crystallization Tx, as well as the elastic moduli in this system can give a useful guideline for the chemical design of desirable bulk metallic glasses (BMGs) with tunable physical properties in advance. The relationship between Tg and elastic constants for the La–Al–Co BMGs can be quantitatively described using a microscopic model proposed by T. Egami.

We report on the microstructure, the thermal stability and the mechanical properties of slowly cooled Zr-Nb-Cu-Ni-Al alloys with ductile bcc phase precipitates embedded in a glassy or nanocrystalline matrix. The samples were prepared in form of rods by injection casting into a copper mold. The phase formation and the microstructure of the composite material were investigated by X-ray diffraction, EDX analysis and scanning and transmission electron microscopy. The thermal stability was examined by differential scanning calorimetry and the mechanical behavior was investigated by compression tests under quasistatic loading at room temperature. The formation of bcc phase dendrites and a glassy or nanocrystalline matrix is strongly governed by the alloy composition and the actual cooling rate during solidification. Besides, changes in composition and cooling rate lead to different volume fraction and size of the bcc phase precipitates and, hence, to different values of yield strength, elastic and plastic strain. The samples with nanocrystalline matrix show a homogeneous distribution of the bcc phase precipitates over the whole cross-section and exhibit higher yield strength and plastic strain than the samples containing an amorphous matrix. Illustrated by the presented results we show the possibility of obtaining tailored mechanical properties by control of composition and solidification conditions.

The bulk amorphous Fe-based alloy with the nominal composition Fe65.5Cr4Mo4Ga4P12C5B5.5 was obtained by copper mold casting in different shapes: cylindrical rods with diameters up to 2.5 mm and discs with 10 mm diameter and 1 mm thickness. This alloy exhibits good soft magnetic properties. Using electrochemical investigations we found that the corrosion resistance of this alloy is better than that of usual FeSi steel used for magnetic applications. Beside magnetic properties and corrosion resistance, this alloy exhibits also good mechanical properties. These were investigated by compression tests, nanoindentation and by an ultrasonic technique. The Young's modulus E was found to be around 160 GPa, the yield strength σy is around 2.3 GPa and the fracture strength σf is around 3.23 GPa, together with an elastic strain εe= 1.5% and a fracture strain εf= 2.3%. The hardness was found to be around 10 GPa.