Yes / A novel process chain for serial production of polymer-based devices incorporating both micro- and nano-scale features is proposed. The process chain is enabled by the use of Zr-based bulk metallic glasses (BMG) to achieve the necessary level of compatibility and complementarity between its component technologies. It integrates two different technologies, namely laser ablation and focused ion beam (FIB) milling for micro-structuring and sub-micron patterning, respectively, thus to fabricate inserts incorporating different length scale functional features. Two alternative laser sources, namely nano-second (NS) and pico-second (PS) lasers, were considered as potential candidates for the first step in this master-making process chain. The capabilities of the component technologies together with some issues associated with their integration were studied. To validate the replication performance of the produced masters, a Zr-based BMG insert was used to produce a small batch of micro-fluidic devices by micro-injection moulding. Furthermore, an experimental study was also carried out to determine whether it would be possible by NS laser ablation to structure the Zr-based BMG workpieces with a high surface integrity whilst retaining the BMG's non-crystalline morphology. Collectively, it was demonstrated that the proposed process chain could be a viable fabrication route for mass production of polymer devices incorporating different length scale features.

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Bulk metallic glasses (BMGs) are a new class of structural materials and exhibit unique combinations of mechanical properties. As a result, their mechanical behavior has been an active area of scientific pursuit in the recent past and considerable emphasis has been paid to understand plastic deformation in them. It is now well accepted that shear transformation zones (STZs), aided by free volume, are the fundamental carriers of plasticity. At a microscopic level, deformation at low temperatures and high stresses tends to localize into shear bands. Most BMGs posses high fracture toughness despite high yield strengths and poor global ductility. However, the micro-mechanisms of fracture and fatigue in this new class of materials are not fully understood yet. The overall objective of this study is to provide insights into the fracture and fatigue response of amorphous alloys, which is important both from scientific and technological perspectives. The key questions we seek to answer through this study are the following. Do amorphous alloys undergo a ductile-brittle transition (DBT), and if so what are the reasons for it? What are the parameters that influence fatigue crack initiation in amorphous alloys and whether fatigue life can be improved by surface treatments? A related question is whether the BMGs are susceptible to deformation-induced crystallization (DIC). A Zr-based BMG, Zr41.2Ti13.75Cu12.5Ni10Be22.5 was utilized to conduct this study. By comparing the fracture and fatigue behaviors in the as-cast and annealed states {annealing was carried out below the glass transition temperature (Tg) because of established embrittlement effects}, we seek to provide answers for the questions posed above. We begin by examining the influence of temperature on the toughness of BMGs. Impact toughness measurements show that the annealed samples, which are brittle at room temperature, recover the lost toughness beyond a critical temperature (TDB) and exhibit a sharp DBT. However, the hardness remains unaffected across the TDB. Fractography reveals nano-scale patterning and cleavage fracture in the brittle state, while the formation of thick vein-patterns and shear fracture are characteristics of the ductile state of the annealed samples. We explore various micro-mechanistic possibilities for explaining the features of this transition, including a critical Poisson’s ratio-toughness correlation. Next, to understand the origins of fatigue crack initiation, we study the un-notched fatigue response of as-cast and sub-Tg annealed Zr-based BMG specimens. Because of embrittlement and nano-crystallization at the crack initiation region, the annealed specimens exhibit a lower fatigue life than the as-cast specimens. Shot-peening of the as-cast specimens did not exhibit significant improvement in their fatigue performance because of competing effects between the compressive residual stress field (CRSF) and deformation-induced softening. To further investigate surface and repeated loading effects, the tribological response of the as-cast Zr-based BMG was compared with specimens annealed above and below the Tg. A good correlation between the hardness (increasing as a function of the annealing temperature) and wear rate was obtained. The formation and peeling of the oxide layer formed during testing was the primary wear mechanism in all the specimens. Lastly, crystallization was observed within the deformed region of the as-cast Zr-based BMG repeatedly scratched with a sharp diamond indenter. But, transmission electron microscopy (TEM) does not reveal any evidence of crystallization within the indents formed within an electron transparent film formed by laser deposition of the as-cast Zr-based BMG. Absence of crystallization in deformed regions obtained by designing critical experiments, which avoid artifacts generated during sample preparation, suggests that the occasional observation of DIC might be an exception rather than the rule in BMGs.

Bulk metallic glasses represent a newly developed class of materials. Some metallic glasses possess combinations of very good or even excellent mechanical, chemical and/or magnetic properties uncovering a broad range of both industrial and vital applications. Besides all advantages metallic glasses have also significant drawbacks, which have to be overcome for commercial application. Apart from low critical thicknesses, brittleness and chemical inhomogeneity one important problem of metallic glasses is the lack of an appropriate theory describing their structure. Therefore, the search for new glass forming compositions as well as the improving of existing ones occurs at present by means of trial-and-error methods and a number of empirical rules. Empirical rules for good glass-forming ability of bulk metallic glasses have been established in recent years by Inoue and Egami. Two of these rules, (i) Preference of more than 3 elements and (ii) Need of more than 12 % radii difference of base elements, seem to be closely related to topological (geometrical) criteria. From this point of view topological parameters contribute essentially to the glass-forming ability. The third rule (iii) demands a negative mixing enthalpy of base elements and refers to the chemical interaction of the atoms. The generalized Bernal’s model (hard-sphere approximation) was used for the simulation of monatomic, binary and multi-component structures. Excluding chemical interaction, this method allows the investigation of topological criteria of the glass-forming ability. Bernal’s hard-sphere model was shown to be a good approximation for bulk metallic glasses and metallic liquids and yields good coincidence of experimental and theoretical results. • The Laguerre (weighted Voronoi) tessellation technique was used as the main tool for the structural analysis. Due to very complex structures it is impossible to determine the structure of bulk metallic glasses by means of standard crystallographic methods. • Density, radial distribution function, coordination number and Laguerre polyhedra analysis confirm amorphism of the simulated structures and are in a good agreement with available experimental results. • The ratio of the fractions of non-crystalline to crystalline Laguerre polyhedra faces was introduced as a new parameter . This parameter reflects the total non-crystallinity of a structure and the amount of atomic rearrangements necessary for crystallization. Thus, the parameter is related to the glass-forming ability. It depends strongly on composition and atomic size ratio and indicates a region of enhanced glass-forming ability in binary mixtures at 80 % of small atoms and atomic size ratio of 1.3. All found maxima of parameter for ternary mixtures have compositions and size ratios which are nearly the same as for the binary mixture with the maximum value of . • A new method of multiple-compression was introduces in order to test the tendency towards densification and/or crystallization of the simulated mixtures. The results of the multiple-compression of monatomic mixtures indicate a limiting value of about 0.6464 for the density of the amorphous state. Further densification is necessarily connected to formation and growth of nano-crystalline regions. • The results of the multiple-compression for binary mixtures shows a new maximum of the density at the size ratio of 1.3 and 30 % to 90 % of small atoms. This maximum indicates a local island of stability of the amorphous state. The maximal receivable density without crystallization in this region is enhanced compared to neighbouring regions. • The comparison of the parameter and the density to the distribution of known binary bulk metallic (metal-metal) glasses clearly shows that both parameters play a significant role in the glass-forming ability. • The polyhedra analysis shows regions with enhanced fraction of the icosahedral short-range order (polyhedron (0, 0, 12)) in the binary systems with the maximum at 80 % of small atoms and size ratio of 1.3. Comparison of the distribution of the (0, 0, 12) polyhedra to the distribution of known binary metallic (metal-metal) glasses and to the parameter shows that icosahedral short-range order is not related to the glass-forming ability and is a consequence of the high non-crystallinity (high values of ) of the mixtures and non vice versa. Results for the ternary mixtures confirm this observation. • A new approach for the calculation of the mixing enthalpy is proposed. The new method is based on the combination of Miedema’s semi-empirical model and Laguerre tessellation technique. The new method as well as 6 other methods including the original Miedema’s model were tested for more than 1400 ternary and quaternary alloys. The results show a better agreement with experimental values of the mixing enthalpy for the new model compared to all other methods. The new model takes into account the local structure at atom site and can be applied to all metallic alloys without additional extrapolations if the atomic structure of the considered alloy is known from a suitable atomistic structure model.

Plastic flow in bulk metallic glasses (BMGs) localizes into narrow bands, which, in the absence of a microstructure that could obstruct them, propagate unhindered under tensile loading. In constrained deformation conditions such as indentation and at notch roots, extensive shear band formation can occur. A key issue in the context of fracture of BMGs that is yet to be understood comprehensively is how their toughness is controlled by various state parameters. Towards this end, the change in fracture toughness and plasticity with short term annealing above and below the glass transition temperature, Tg, is studied in a Zr-based BMG. Elastic properties like shear modulus, Poisson's ratio as well as parameters defining the internal state like the fictive temperature, Tf, density, and free volume are measured and correlation with the toughness was attempted at. While the elastic properties may help in distinguishing between tough and brittle glasses, they fail to reveal the reasons behind the toughness variations. Spherical-tip nanoindentation and microindentation tests were employed to probe the size, distributions and activation energies of the microscopic plastic carriers with the former and shear band densities with the latter. Results indicate that specimens annealed at a higher temperature, Ta, exhibit profuse shear banding with negligible changes in the local yield strengths. Statistical analysis of the nanoindentation data by incorporating the nucleation rate theory and the results of the cooperative shear model (CSM), reveals that short term annealing doesn't alter the shear transformation zone (STZ) size much. However, density estimates indicate changes in the free volume content across specimens. A model combining STZ activation and free volume accumulation predicts a higher rate in the reduction of the cumulative STZ activation barrier in specimens with a higher initial free volume content. Of the macroscopic physical properties, the specimen density is revealed to be a useful qualitative measure of enhancement in fracture toughness and plasticity in BMGs. We turn our attention next to the brittle fracture in BMGs, with the specific objective of understanding the mechanisms of failure. For this purpose, mode I fracture experiments were conducted on embrittled BMG samples and the fracture surface features were analyzed in detail. Wallner lines, which result from the interaction between the propagating crack front and shear waves emanating from a secondary source, were observed on the fracture surface and geometric analysis of them indicates that the maximum crack velocity to be ~800 m/s, which corresponds to ~0.32 times the shear wave speed. Fractography reveals that the sharp crack nucleation at the notch tip occurs at the mid-section of the specimens with the observation of flat and half-penny shaped cracks. On this basis, we conclude that the crack initiation in brittle BMGs occurs through hydrostatic stress assisted cavity nucleation ahead of the notch tip. High magnification scanning electron and atomic force microscopies of the dynamic crack growth regions reveal highly organized, nanoscale periodic patterns with a spacing of ~79 nm. Juxtaposition of the crack velocity with this spacing suggests that that the crack takes ~10-10 s for peak-to-peak propagation. This, and the estimated adiabatic temperature rise ahead of the propagating crack tip that suggests local softening, are utilized to critically discuss possible causes for the nanocorrugation formation. The Taylor’s fluid meniscus instability is unequivocally ruled out. Then, two other possible mechanisms, viz. (a) crack tip blunting and resharpening through nanovoid nucleation and growth ahead of the crack tip and eventual coalescence, and (b) dynamic oscillation of the crack in a thin slab of softened zone ahead of the crack-tip, are critically discussed. One way of alleviating the fracture-related issues in BMGs is to impart a microstructure to it, which would either impede the growth of shear bands or promote the multiplication of them. One such approach is through the BMG composites (BMGCs) route, wherein a crystalline second phase incorporated in the BMG matrix. There is a need to study the effects of reinforcement content, size and distribution on the mechanical behavior of the BMGC so as to achieve an optimum combination of strength and ductility. For this purpose, an investigation into the microstructure and tensile properties of Zr/Ti-based BMG composites of the same composition, but produced by different routes, was conducted so as to identify “structure–property” connections in these materials. This was accomplished by employing four different processing methods—arc melting, suction casting, semi-solid forging and induction melting on a water-cooled copper boat—on composites with two different dendrite volume fractions, Vd. The change in processing parameters only affects microstructural length scales such as the interdendritic spacing, λ, and dendrite size, δ, whereas compositions of the matrix and dendrite are unaffected. Broadly, the composite’s properties are insensitive to the microstructural length scales when Vd is high (∼75%), whereas they become process dependent for relatively lower Vd (∼55%). Larger δ in arc-melted and forged specimens result in higher ductility (7–9%) and lower hardening rates, whereas smaller dendrites increase the hardening rate. A bimodal distribution of dendrites offers excellent ductility at a marginal cost of yield strength. Finer λ result in marked improvements in both ductility and yield strength, due to the confinement of shear band nucleation sites in smaller volumes of the glassy phase. Forging in the semi-solid state imparts such a microstructure.

The ferromagnetic bulk metallic glasses (BMGs) started to be investigated only in the last 10 years.They are difficult to cast, but their properties are uniques. The work deals with casting, mechanical and soft magnetic properties of new Fe-based BMGs. Such alloys can be cast directly in samples with various geometries and they can be use as magnetic parts in different devices.

Bulk metallic glasses represent a newly developed class of materials. Some metallic glasses possess combinations of very good or even excellent mechanical, chemical and/or magnetic properties uncovering a broad range of both industrial and vital applications. Besides all advantages metallic glasses have also significant drawbacks, which have to be overcome for commercial application. Apart from low critical thicknesses, brittleness and chemical inhomogeneity one important problem of metallic glasses is the lack of an appropriate theory describing their structure. Therefore, the search for new glass forming compositions as well as the improving of existing ones occurs at present by means of trial-and-error methods and a number of empirical rules. Empirical rules for good glass-forming ability of bulk metallic glasses have been established in recent years by Inoue and Egami. Two of these rules, (i) Preference of more than 3 elements and (ii) Need of more than 12 % radii difference of base elements, seem to be closely related to topological (geometrical) criteria. From this point of view topological parameters contribute essentially to the glass-forming ability. The third rule (iii) demands a negative mixing enthalpy of base elements and refers to the chemical interaction of the atoms. The generalized Bernal’s model (hard-sphere approximation) was used for the simulation of monatomic, binary and multi-component structures. Excluding chemical interaction, this method allows the investigation of topological criteria of the glass-forming ability. Bernal’s hard-sphere model was shown to be a good approximation for bulk metallic glasses and metallic liquids and yields good coincidence of experimental and theoretical results. • The Laguerre (weighted Voronoi) tessellation technique was used as the main tool for the structural analysis. Due to very complex structures it is impossible to determine the structure of bulk metallic glasses by means of standard crystallographic methods. • Density, radial distribution function, coordination number and Laguerre polyhedra analysis confirm amorphism of the simulated structures and are in a good agreement with available experimental results. • The ratio of the fractions of non-crystalline to crystalline Laguerre polyhedra faces was introduced as a new parameter . This parameter reflects the total non-crystallinity of a structure and the amount of atomic rearrangements necessary for crystallization. Thus, the parameter is related to the glass-forming ability. It depends strongly on composition and atomic size ratio and indicates a region of enhanced glass-forming ability in binary mixtures at 80 % of small atoms and atomic size ratio of 1.3. All found maxima of parameter for ternary mixtures have compositions and size ratios which are nearly the same as for the binary mixture with the maximum value of . • A new method of multiple-compression was introduces in order to test the tendency towards densification and/or crystallization of the simulated mixtures. The results of the multiple-compression of monatomic mixtures indicate a limiting value of about 0.6464 for the density of the amorphous state. Further densification is necessarily connected to formation and growth of nano-crystalline regions. • The results of the multiple-compression for binary mixtures shows a new maximum of the density at the size ratio of 1.3 and 30 % to 90 % of small atoms. This maximum indicates a local island of stability of the amorphous state. The maximal receivable density without crystallization in this region is enhanced compared to neighbouring regions. • The comparison of the parameter and the density to the distribution of known binary bulk metallic (metal-metal) glasses clearly shows that both parameters play a significant role in the glass-forming ability. • The polyhedra analysis shows regions with enhanced fraction of the icosahedral short-range order (polyhedron (0, 0, 12)) in the binary systems with the maximum at 80 % of small atoms and size ratio of 1.3. Comparison of the distribution of the (0, 0, 12) polyhedra to the distribution of known binary metallic (metal-metal) glasses and to the parameter shows that icosahedral short-range order is not related to the glass-forming ability and is a consequence of the high non-crystallinity (high values of ) of the mixtures and non vice versa. Results for the ternary mixtures confirm this observation. • A new approach for the calculation of the mixing enthalpy is proposed. The new method is based on the combination of Miedema’s semi-empirical model and Laguerre tessellation technique. The new method as well as 6 other methods including the original Miedema’s model were tested for more than 1400 ternary and quaternary alloys. The results show a better agreement with experimental values of the mixing enthalpy for the new model compared to all other methods. The new model takes into account the local structure at atom site and can be applied to all metallic alloys without additional extrapolations if the atomic structure of the considered alloy is known from a suitable atomistic structure model.

The glass-forming composition ranges in Al-La-Ni and Mg-TM (Cu, Zn)-Y alloys were predicted using Miedema’s model. Glass-forming abilities of Al-La-Ni alloys and Mg-Cu-RE alloys were studied in terms of reduced glass transition temperature (Trg), supercooled liquid region (∆Tx) and γ parameters. The glass-forming ability parameters of Mg-Cu-RE (RE: rare-earth) alloys were correlated with Mendeleev number. The Miedema model has been used to determine glass-forming composition range in binary Al-La, Al-Ni and La-Ni alloy systems and the ternary Al-La-Ni system by neglecting the ternary interactions. The glass-forming composition range for Al-La, Al-Ni and La-Ni alloy systems extends from 5 to 90 at% La, 30 to 80 at% Ni and 5 to 95 at% Ni, respectively. In these systems the predicted glass-forming composition range is wider than the experimentally observed range. Miedema model, restricting the difference of enthalpy of formation between the amorphous and solid solution phases to within –10000 J/mole to –55000 J/mole gives rise to better prediction of glass-forming composition range compared to the original models. The concept of mixing enthalpy and mismatch entropy has been used in order to quantify Inoue’s criteria of glass formation. The mixing enthalpy and normalised mismatch entropy of the ternary Al-La-Ni alloys, calculated by the extended regular solution model, vary between –12 to –40 kJ/mol and 0.16 to 0.65, respectively. The enthalpy contour plot has been constructed to distinguish the glass-forming compositions on the basis of the increasing negative enthalpy of the composition. Six Al rich Al-La-Ni alloys with nominal compositions Al89La6Ni5, Al85La10Ni5, Al85La5Ni10, Al82La8Ni10, Al80La10Ni10 and Al60La20Ni20 three La rich Al-La-Ni alloys with nominal compositions Al34La33Ni33, Al40La40Ni20 and Al25La50Ni25 have been chosen from the Al-La-Ni ternary phase diagram, to study the glass-forming ability of Al-La-Ni ternary alloy system and the correlation between La-based and Al-based glasses. All the alloys have been prepared using arc melting unit. All the alloy ribbons have been prepared using single-wheel vacuum melt-spinning unit. Two different wheel speeds of 20 m/s and 40 m/s were used for preparing ribbons of all the nine alloys. All the Al-La-Ni compositions, excluding equi-atomic composition (Al34La33Ni33) and Al60La20Ni20, give rise to amorphous phases. The supercooled liquid region and reduced glass transition temperature of this system increases with a decrease in Al content and an increase in La content. The glass-forming ability of the Al rich Al-La-Ni alloys is lower than that of the La-rich Al-La-Ni alloys. The glass-forming ability has been explained by taking into account the binary heat of mixing and the atomic radius mismatch of the constituent elements. Preferential crystallisation takes place during the heat treatment of glassy ribbons. The crystalline products are partially influenced by composition and binary heat of mixing between elements. Mg65Cu25Y10 alloy is a classical glass former of a family of Mg-based alloys. The partial or complete substitution of Y with other rare earth elements has been introduced to correlate the Mendeleev Number with the glass-forming ability parameters: reduced glass transition temperatures (Trg = Tg/Tl), supercooled liquid regions (∆Tx = Tx – Tg) and γ-criterion (TX/(Tg + Tm)). Mg-Cu-RE alloys with nominal compositions Mg65Cu25Y10, Mg65Cu25Y5Gd5, Mg65Cu25Y5Nd5, Mg65Cu25Gd10 and Mg65Cu25Nd10 were chosen for this work. The high reduced glass transition temperature, wider supercooled liquid region and higher γ value of Mg-Cu-Gd-Y amorphous alloy compared to Mg-Cu-Y and Mg-Cu-Nd-Y systems indicates that Mg-Cu-Gd-Y alloys possess higher glass-forming ability. The devitrification of all Mg-Cu-RE glassy alloys used for this work give rise to Mg2Cu (oF48) phase, which is known as anti-Laves phase. The glass-forming composition range for binary and ternary Mg-Cu-Y systems was calculated using Miedema’s model. The development of accurate methods of prediction of glass-forming ability in metallic systems is an important challenge. Pettifor has pioneered the Structure Mapping approach to binary intermetallics. The Pettifor approach can be adapted to the designing of bulk metallic glasses (BMGs). This method has been used to design Al-based and Mg-based BMG’s. Pettifor introduced an integer parameter to characterize the elements, which he called the Mendeleev Number. Essentially, Pettifor’s scheme orders the elements in a sequence of increasing electronegativity. With respect to Mendeleev Number, the Mg-Cu-RE system can be regarded as a binary system, because of the closeness of Mg and Cu (Mg:73, Cu:72, Y:25, Gd:27 and Nd:30). For this system, Mendeleev Number is a more effective parameter than atomic size (Mg: 1.60 Å, Cu: 1.27 Å), as a predictor of glass-forming ability. The effect of Y and rare earth elements on glass forming ability is similar. The atomic number of Y (39) is away from that of the rare earth elements and the Mendeleev Number of Y (25) comes in between those of the rare earth elements. Mg-Zn-Y system is an interesting system for researchers because of higher strength of these alloys. This system draws the crystallographers’ attention due to its composition-dependent structure variations. The Mg-rich RS/PM Mg-Zn-Y alloys yield superior mechanical properties. Therefore, the Mg-rich Mg-Zn-Y system has been chosen to study the microstructural evolution, even though the theoretical calculations for the glass-forming composition range for the Mg-Zn-Y system shows that this system is not a good glass former. Mg-Zn-Y system with nominal compositions Mg97Zn1Y2, Mg97Zn2Y1, Mg97−xZn1Y2Zrx and Mg92Zn6.5Y1.5 were chosen to study the microstructural evolution of these alloys. A small increase in Zn amount (above 2 at.%) in Mg-rich Mg-Y system results in quasicrystalline particles embedded in the matrix, whereas the addition of Zn up to 2 at.% leads to microstructural changes in the α-Mg solid solution.