An embodiment relates to a method comprising overmolding a bulk-solidifying amorphous alloy on a preform of another material than the bulk-solidifying amorphous alloy to form a bulk-solidifying amorphous alloy overmolded preform. Another embodiment relates to an article comprising an overmolded shell comprising the bulk-solidifying amorphous alloy on a preform of another material than the bulk-solidifying amorphous alloy. The preform could be made of a crystalline or amorphous metal or alloy such as aluminum, stainless steel, copper or beryllium.

In one embodiment, the invention provides a process for thermoplastic forming of a metallic glass. For example, in one embodiment, the invention provides a process for thermoplastic forming of a metallic glass ribbons having a thickness of between about 50 to about 200 microns. Related articles of manufacture and processes for customizing articles in accordance with the process as described herein are also provided.

The disclosure provides PdCuP metallic glass-forming alloys and metallic glasses comprising at least one of Ag, Au, and Fe, where the alloys are capable of forming metallic glass rods with diameters in excess of 3 mm, and in some embodiments 26 mm or larger.

The disclosure provides PtCuP glass-forming alloys bearing at least one of B, Ag, and Au, where each of B, Ag, and Au can contribute to improve the glass forming ability of the alloy in relation to the alloy that is free of these elements. The alloys are capable of forming metallic glass rods with diameters in excess of 3 mm, and in some embodiments 50 mm or larger. The alloys and metallic glasses can satisfy platinum jewelry hallmarks PT750, PT800, PT850, and PT900.

A process for producing a molded material that can form metallic glass material in a state of lower viscosity, and can manufacture a small structure of several 10 m or less in a comparatively short time while precisely controlling shape thereof, by the process comprising a heating step of heating supercooled state metallic glass material or a solid metallic glass material at a temperature increase rate of 0.5 K/s to a temperature at or higher than a temperature at which a crystallization process for a supercooled liquid of the metallic glass material begins, and a molding step of transfer molding the metallic glass material until the crystallization process for the supercooled liquid of the metallic glass material has been completed. In addition, the purpose is also to provide the molded material that has been formed by this process, a wavefront control element, and a diffraction grating.

Embodiments herein relate to methods and apparatuses for casting of BMG-containing parts. The surfaces of the mold that come into contact with the molten amorphous alloy comprise an amorphous material. In accordance with the disclosure, the mold may be coated with an amorphous material, e.g., to reduce, minimize, or eliminate crystallization of the molded BMG-containing part. The surfaces of the mold are coated, in certain aspects, so as to reduce or eliminate potential grain-boundary nucleation sites for BMG crystallization. The amorphous material may be selected based on the particular molten amorphous alloy to be cast, e.g., based on the wetting properties, the melting and cooling properties, etc.

Embodiments herein relate to forming nano- and/or micro-replication directly embossed in a bulk solidifying amorphous alloy comprising a metal alloy by superplastic forming of the bulk solidifying amorphous alloy at a temperature greater than a glass transition temperature (Tg) of the metal alloy.

Embodiments herein relate to a method of making roll formed objects of a bulk solidifying amorphous alloy comprising a metal alloy, and articles thereof. The roll forming includes forming a portion of the bulk solidifying amorphous alloy at a temperature greater than a glass transition temperature (Tg) of the metal alloy. The roll forming is done such that a time-temperature profile of the portion during the roll forming does not traverse through a region bounding a crystalline region of the metal alloy in a time-temperature-transformation (TTT) diagram of the metal alloy.

Described herein is a method of producing an alloy. The method includes pouring a stream of molten mixture of component elements of the alloy, separating the stream into discrete pieces, solidifying the discrete pieces by cooling before the discrete pieces contact any liquid or solid. Also described herein is another method of producing an alloy. This method includes pouring and solidifying a stream of molten mixture of component elements of the alloy into a rod or pulling a rod from a molten mixture of component elements of the alloy, before the rod contacts any liquid or solid, separating the rod into discrete pieces. An apparatus suitable for carrying out the methods above can include a container from which the molten stream is poured or the solid rod extends, one or more coil, conductive plates, a laser source, or an electron beam source arranged around the molten stream or the solid rod and configured to separate the molten stream or the solid rod into discrete pieces.

A method of fabricating a nanoporous metal structure, such as a nanoporous metal (NMP) supported Pd catalyst suitable for use in a direct methanol fuel cell (DMFC), is includes the steps of (a) providing a piece of Au.sub.55Cu.sub.25Si.sub.20 alloy glass ribbon with a thickness of 50 m, (b) dealloying the piece of alloy glass ribbon by reacting with iron (III) chloride solution to form a free-standing NPM ribbon, (c) depositing a thin film of PdCo of a thickness of 100 nm on the NPM ribbon by RF magnetron sputtering with Pd.sub.0.5Co.sub.0.5 (atomic percent) as target in an argon atmosphere, and (d) electrochemically dissolving some of the Co on the thin film of PdCo to induce migration of Au from the NPM ribbon to the thin layer of PdCo.