Methods of making high-strength, lightweight alloy components capable of high temperature performance comprising aluminum, silicon, and iron and/or nickel are provided. A high-energy stream, such as a laser or electron beam, may be selectively directed towards a precursor material to melt a portion of the precursor material in a localized region. The molten precursor material is cooled at a rate of greater than or equal to about 1.010.sup.5 K/second to form a solid high-strength, lightweight alloy component comprising a stable ternary cubic phase having high heat resistance and high strength. The stable ternary phase may be Al.sub.xFe.sub.ySi.sub.z, where x ranges from about 4 to about 5 or about 7.2 to about 7.6, y is about 1.5 to about 2.2, and z is about 1. The stable ternary phase may also be Al.sub.6Ni.sub.3Si. Materials and components, such as automotive components, made from such methods are also provided.

A powder of particles can include an aluminum alloy where the aluminum alloy is at least approximately eighty percent by weight of the powder; and one or more metals selected from a group consisting of alkali metals, alkaline earth metals, and basic metals having an atomic number equal to or greater than 31, where the one or more metals selected from the group total at least approximately two percent by weight of the powder; where each of the particles includes individual grains formed of a grain material that includes the aluminum alloy, where each of the particles includes grain boundary material that includes the one or more metals selected from the group, and where the grain boundary material bounds the individual grains.

A powder of particles can include an aluminum alloy where the aluminum alloy is at least approximately eighty percent by weight of the powder; and one or more metals selected from a group consisting of alkali metals, alkaline earth metals, and basic metals having an atomic number equal to or greater than 31, where the one or more metals selected from the group total at least approximately two percent by weight of the powder; where each of the particles includes individual grains formed of a grain material that includes the aluminum alloy, where each of the particles includes grain boundary material that includes the one or more metals selected from the group, and where the grain boundary material bounds the individual grains.

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.

The present invention provides a magnetic core part by which failures such as cracks do not occur even if the magnetic core part contains 90% by mass or more of an amorphous metal powder. The magnetic core part is formed by thermoset molding at least one magnetic powder selected from an amorphous metal powder alone and an amorphous metal powder coated with an insulating material, and a thermosetting binder resin. The magnetic core part contains the magnetic powder in an amount of 90% by mass or more and 99% by mass or less with respect to the total amount of the magnetic powder and the thermosetting binder resin.

The present invention provides a magnetic core part by which failures such as cracks do not occur even if the magnetic core part contains 90% by mass or more of an amorphous metal powder. The magnetic core part is formed by thermoset molding at least one magnetic powder selected from an amorphous metal powder alone and an amorphous metal powder coated with an insulating material, and a thermosetting binder resin. The magnetic core part contains the magnetic powder in an amount of 90% by mass or more and 99% by mass or less with respect to the total amount of the magnetic powder and the thermosetting binder resin.

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.

An electromagnetic wave shielding thin film for shielding from electromagnetic waves generated in an electronic part is provided. The electromagnetic wave shielding thin film includes metal plate which has elastic limit of 1% or more, strength of 1000 MPa or more, and a volume fraction of an amorphous phase of 50% or more.

Disclosed herein are embodiments of rapidly solidified alloys that comprise aluminum, a rare earth element, one or more additional alloying elements, such as aluminum, and an optional additive component. The alloy embodiments exhibit a unique microstructure as compared to microstructures obtained from other alloys that are not rapidly cooled. The disclosed aluminum-rare earth element alloys also exhibit improved mechanical properties without the need for post-processing heat treatments and further do not exhibit substantial coarsening.

Disclosed herein are embodiments of rapidly solidified alloys that comprise aluminum, a rare earth element, one or more additional alloying elements, such as aluminum, and an optional additive component. The alloy embodiments exhibit a unique microstructure as compared to microstructures obtained from other alloys that are not rapidly cooled. The disclosed aluminum-rare earth element alloys also exhibit improved mechanical properties without the need for post-processing heat treatments and further do not exhibit substantial coarsening.