Provided is an iron-based amorphous alloy and a method of manufacturing the same. More particularly, provided is an high carbon iron-based amorphous alloy expressed by a general formula Fe.sub.C.sub.SiBxPyCrz, wherein , , , x, y and z are atomic % of iron (Fe), carbon (C), silicon (Si), boron (B), phosphorus (P), and chrome (Cr) respectively, wherein is expressed by =100(++x+y+z) atomic %, is expressed by 13.5 atomic %17.8 atomic %, is expressed by 0.30 atomic %1.50 atomic %, x is expressed by 0.1 atomic %x4.0 atomic %, y is expressed by 0.8 atomic %y7.7 atomic %, and z is expressed by 0.1 atomic %z3.0 atomic %.

The present disclosure provides specified ranges in the FeMoNiCrPCB alloys such that the alloys are capable of forming bulk glasses having unexpectedly high glass-forming ability. The critical rod diameter of the disclosed alloys is at least 10 mm.

A soft magnetic powder of the invention has a composition represented by Fe.sub.100-a-b-c-d-e-fCu.sub.aSi.sub.bB.sub.cM.sub.dM.sub.eX.sub.f (at %) [wherein M is Nb, W, Ta, Zr, Hf, Ti, or Mo, M is V, Cr, Mn, Al, a platinum group element, Sc, Y, Au, Zn, Sn, or Re, X is C, P, Ge, Ga, Sb, In, Be, or As, and a, b, c, d, e, and f are numbers that satisfy the following formulae: 0.1a3, 0<b30, 0<c25, 5b+c30, 0.1d30, 0e10, and 0f10], wherein a crystalline structure having a particle diameter of 1 nm or more and 30 nm or less is contained in an amount of 40 vol % or more, and the difference in the coercive force of the powder after classification satisfies predetermined conditions.

A method of manufacturing an iron-based alloy coating is provided, which includes (a) providing an iron-based alloy powder having a chemical formula of Fe.sub.aCr.sub.bMo.sub.cSi.sub.dB.sub.eY.sub.f, wherein 48a50; 21b23; 18c20; 2d3; 2e4; and 0<f2. The method also includes step (b) thermal spraying the iron-based alloy powder to form an amorphous iron-based alloy coating, and step (c) laser re-melting the amorphous iron-based alloy coating, wherein the iron-based alloy coating is densified and remains amorphous.

Systems and methods in accordance with embodiments of the invention fabricate objects including amorphous metals using techniques akin to additive manufacturing. In one embodiment, a method of fabricating an object that includes an amorphous metal includes: applying a first layer of molten metallic alloy to a surface; cooling the first layer of molten metallic alloy such that it solidifies and thereby forms a first layer including amorphous metal; subsequently applying at least one layer of molten metallic alloy onto a layer including amorphous metal; cooling each subsequently applied layer of molten metallic alloy such that it solidifies and thereby forms a layer including amorphous metal prior to the application of any adjacent layer of molten metallic alloy; where the aggregate of the solidified layers including amorphous metal forms a desired shape in the object to be fabricated; and removing at least the first layer including amorphous metal from the surface.

A soft magnetic powder has a composition represented by Fe.sub.100-a-b-c-d-e-fCu.sub.aSi.sub.bB.sub.cM.sub.dM.sub.eX.sub.f (at %) (wherein M is Nb, W, Ta, Zr, Hf, Ti, or Mo, M is V, Cr, Mn, Al, a platinum group element, Sc, Y, Au, Zn, Sn, or Re, X is C, P, Ge, Ga, Sb, In, Be, or As, and a, b, c, d, e, and f are numbers that satisfy the following formulae: 0.1a3, 0<b30, 0<c25, 5b+c30, 0.1d30, 0e10, and 0f10), wherein a crystalline structure having a particle diameter of 1 nm or more and 30 nm or less is contained in an amount of 40 vol % or more, and the Vickers hardness of the particles is 1000 or more and 3000 or less.

Various embodiments provide methods and apparatus for forming bulk metallic glass (BMG) articles using a mold having a stationary mold part and a movable mold part paired to form a mold cavity. A molten material can be injected to fill the mold cavity. The molten material can then be cooled into a BMG article at a desired cooling rate. While injecting and/or cooling the molten material, the movement of the movable mold part can be controlled, such that a thermal contact between the molten material and the mold can be maintained. BMG articles can be formed without forming an underfilled part. Additional structural features can be imparted in the BMG article during formation. At least a portion of the formed BMG article can have an aspect ratio (first dimension/second dimension) of at least 10 or less than 0.1.

A molten metal temperature control method includes: with respect to relations among a spheroidization distance traveled by a molten metal of an alloy from a nozzle tip to a position where the molten metal turns into droplets, the temperature of the molten metal inside the crucible, and a pressure acting on the molten metal inside the crucible, obtaining a relation between the temperature and the spheroidization distance at a predetermined pressure, and setting a predetermined temperature range of the temperature; measuring a spheroidization distance when discharging the molten metal from the crucible at the predetermined pressure, and specifying a temperature corresponding to the measured spheroidization distance; and comparing the specified temperature and the predetermined temperature range, and when the specified temperature is outside the predetermined temperature range, controlling the specified temperature so as to be within the predetermined temperature range by adjusting the temperature inside the crucible.

The invention provides a method of producing an amorphous alloy ribbon, the method including a step of producing an amorphous alloy ribbon by discharging a molten alloy through a rectangular opening of a molten metal nozzle having a molten metal flow channel along which the molten alloy flows, the opening being an end of the molten metal flow channel, onto a surface of a rotating chill roll, in which, among wall surfaces of the molten metal flow channel, a maximum height Rz(t) of a surface t, which is a wall surface parallel to a flow direction of the molten alloy and to a short side direction of the opening, is 10.5 m or less.

To provide TiCu alloy formulations and additive manufacturing process configurations for fabrication of a bulk metallic glass (BMG) product that is biocompatible and antimicrobial, compositions of Ti-based metal alloy powder, comprising: Ti; Cu within a range of 5-30 atomic percent; transition metal within a range of 0-50 atomic percent, wherein such transition metal is one or a plurality of Zr, Nb, Ta, Pd, and Co, are disclosed. Moreover, additive manufacturing processes disclosed herein are capable of fabricating a bulk metallic glass of one or a combination of following phasic structures: fully amorphous microstructure; amorphous beta titanium phase; amorphous copper phase; and amorphous (Ti,M).sub.2Cu phase. The resulting biocompatible metal alloy product may be a medical device, particularly but not limited to a medical implant.