Continuous casting of bulk solidifying amorphous alloys
원문보기
IPC분류정보
국가/구분
United States(US) Patent
등록
국제특허분류(IPC7판)
B22D-011/06
B22D-011/04
B22D-011/045
출원번호
US-0597909
(2012-08-29)
등록번호
US-RE45414
(2015-03-17)
국제출원번호
PCT/US2004/011559
(2004-04-14)
§371/§102 date
20060621
(20060621)
국제공개번호
WO2004/092428
(2004-10-28)
발명자
/ 주소
Johnson, William L.
출원인 / 주소
Crucible Intellectual Property, LLC
대리인 / 주소
Pillsbury Winthrop Shaw Pittman LLP
인용정보
피인용 횟수 :
0인용 특허 :
80
초록
A process and apparatus for continuous casting of amorphous alloy sheets having large sheet thickness using bulk solidifying amorphous alloys are provided. Thick continuous amorphous alloy sheets made of bulk solidifying amorphous alloys are also provided.
대표청구항▼
1. A method for the continuous casting of sheets of an amorphous material comprising: providing a quantity of a bulk a solidifying amorphous alloy at a temperature above the melting temperature of the bulk solidifying amorphous alloy;stabilizing the bulk solidifying amorphous alloy at a casting temp
1. A method for the continuous casting of sheets of an amorphous material comprising: providing a quantity of a bulk a solidifying amorphous alloy at a temperature above the melting temperature of the bulk solidifying amorphous alloy;stabilizing the bulk solidifying amorphous alloy at a casting temperature below the melting temperature (Tm) of the alloy and above the temperature at which crystallization occurs on the shortest time scale for the alloy (TNOSE) such that the bulk solidifying amorphous alloy is in a viscosity regime of about 0.1 to 10,000 poise;introducing the stabilized bulk solidifying amorphous alloy onto a moving casting body such that a continuous sheet of heated bulk solidifying amorphous alloy is formed thereon; andquenching the heated bulk solidifying amorphous alloy at a quenching rate sufficiently fast such that the bulk solidifying amorphous alloy remains in a substantially amorphous phase to form a solid amorphous continuous sheet having a thickness of at least 0.1 mm. 2. The method of claim 1, wherein the viscosity of the bulk solidifying amorphous alloy at the “melting temperature” Tm of the bulk solidifying amorphous alloy is from about 10 to 100 poise. 3. The method of claim 1, wherein the viscosity of the bulk solidifying amorphous alloy at the “melting temperature” Tm of the bulk solidifying amorphous alloy is from about 1 to 1000 poise. 4. The method of claim 1, wherein the critical cooling rate of the bulk solidifying amorphous alloy is less than 1,000° C./sec. 5. The method of claim 1, wherein the critical cooling rate of the bulk solidifying amorphous alloy is less than 10° C./sec. 6. The method of claim 1, wherein the quenching occurs on the casting body. 7. The method of claim 1, wherein the casting body is selected from the group consisting of a wheel, a belt, double-roll wheels. 8. The method of claim 1, wherein the casting body is formed from a material having a high thermal conductivity. 9. The method of claim 1, wherein the casting body is formed of a material selected from the group consisting of copper, chromium copper, beryllium copper, dispersion hardening alloys, and oxygen-free copper. 10. The method of claim 1, wherein the casting body is at least one of either highly polished or chrome-plated. 11. The method of claim 1, wherein the casting body moves at a rate of 0.5 to 10 cm/sec. 12. The method of claim 1, wherein the casting temperature is stabilized in a viscosity regime of 1 to 1,000 poise. 13. The method of claim 1, wherein the casting temperature is stabilized in a viscosity regime of 10 to 100 poise. 14. The method of claim 1, wherein the solid amorphous alloy sheet has a thickness of 0.1 to 10 mm. 15. The method of claim 1, wherein the solid amorphous alloy sheet has a thickness of 0.5 to 3 mm. 16. The method of claim 1, wherein the heated alloy is introduced onto the casting body under pressure. 17. The method of claim 1, wherein the bulk solidifying amorphous alloy can be described as (Zr,Ti)a(Ni,Cu,Fe)b(Be,Al,Si,B)c, where a is in the range of from 30 to 75, b is in the range of from 5 to 60, and c in the range of from 0 to 50 in atomic percentages. 18. The method of claim 17, wherein the bulk solidifying amorphous alloy further comprises up to 20% atomic of at least one additional transition metal selected from the group consisting of Hf, Ta, Mo, Nb, Cr, V, Co. 19. The method of claim 1, wherein the bulk solidifying amorphous alloy ferrous metal based. 20. The method of claim 1 wherein the bulk solidifying amorphous alloy further comprises ductile crystalline phase precipitates. 21. An apparatus comprising: a closed reservoir comprising a nozzle and a plunger, the reservoir configured for stabilizing a bulk solidifying amorphous alloy at a casting temperature below a melting temperature (Tm) of the alloy and above a temperature at which crystallization occurs on the shortest time scale for the alloy (TNOSE) such that the alloy is in a viscosity regime of about 0.1 to 10,000 poise; and at least two quench substrates configured for quenching the alloy at sufficiently fast rate such that the alloy remains in a substantially amorphous phase, to form a solid continuous sheet of the alloy, wherein the at least two quench substrates sandwich the alloy therebetween, wherein the reservoir is positioned vertically to contain the alloy and the nozzle is configured to discharge the alloy in a horizontal direction; wherein the solid continuous sheet has a thickness of at least 0.1 mm and the solid continuous sheet is a bulk solidifying amorphous alloy sheet. 22. The apparatus of claim 21, wherein the viscosity of the alloy at the melting temperature Tm of the alloy is from about 10 to 100 poise. 23. The apparatus of claim 21, wherein the viscosity of the alloy at the melting temperature Tm of the alloy is from about 1 to 1000 poise. 24. The apparatus of claim 21, wherein the critical cooling rate of the alloy is less than 1,000° C./sec. 25. The apparatus of claim 21, further comprising a casting body. 26. The apparatus of claim 25, wherein the casting body comprises a material selected from the group consisting of copper, chromium copper, beryllium copper, dispersion hardening alloys, and oxygen-free copper. 27. The apparatus of claim 25, wherein the casting body moves at a rate of 0.5 to 10 cm/sec. 28. The apparatus of claim 21, wherein the bulk solidifying amorphous alloy is stabilized at a casting temperature such that the alloy is in a viscosity regime of 1 to 1,000 poise. 29. The apparatus of claim 21, wherein the bulk solidifying amorphous alloy is stabilized at a casting temperature such that the alloy is in a viscosity regime of 10 to 100 poise. 30. The apparatus of claim 21, wherein the solid amorphous alloy sheet has a thickness of 0.1 to 10 mm. 31. The apparatus of claim 21, wherein the solid amorphous alloy sheet has a thickness of 0.5 to 3 mm. 32. The apparatus of claim 25, wherein the alloy is introduced onto the casting body under pressure. 33. The apparatus of claim 21, wherein the alloy can be described as (Zr,Ti)a(Ni,Cu,Fe)b(Be,Al,Si,B)c, where a is in the range of from 30 to 75, b is in the range of from 5 to 60, and c in the range of from 0 to 50 in atomic percentages. 34. The apparatus of claim 21, wherein the alloy is ferrous metal based. 35. The apparatus of claim 21 wherein the alloy further comprises ductile crystalline phase precipitates. 36. An apparatus comprising: a closed reservoir comprising a nozzle and a plunger, the reservoir configured for stabilizing a bulk solidifying amorphous alloy at a casting temperature below a melting temperature (Tm) of the alloy and above a temperature at which crystallization occurs on the shortest time scale for the alloy TNOSE) such that the alloy is in a viscosity regime of about 0.1 to 10,000 poise; and at least two quench substrates configured for quenching the alloy at sufficiently fast rate such that the alloy remains in a substantially amorphous phase, to form a solid continuous sheet of the alloy, wherein the at least two quench substrates sandwich the alloy therebetween, wherein the nozzle is positioned with respect to the at least two quench substrates in a manner so as to discharge the alloy in a horizontal direction and cause the alloy to traverse from the nozzle to the at least two quench substrates in a substantially straight line, wherein the solid continuous sheet has a thickness of at least 0.1 mm and the solid continuous sheet is a bulk solidifying amorphous alloy sheet. 37. The apparatus of claim 36, wherein the viscosity of the alloy at the melting temperature Tm of the alloy is from about 10 to 100 poise. 38. The apparatus of claim 36, wherein the viscosity of the alloy at the melting temperature Tm of the alloy is from about 1 to 1000 poise. 39. The apparatus of claim 36, wherein the critical cooling rate of the alloy is less than 1,000° C./sec. 40. The apparatus of claim 36, further comprising a casting body. 41. The apparatus of claim 40, wherein the casting body comprises a material selected from the group consisting of copper, chromium copper, beryllium copper, dispersion hardening alloys, and oxygen-free copper. 42. The apparatus of claim 40, wherein the casting body moves at a rate of 0.5 to 10 cm/sec. 43. The apparatus of claim 36, wherein the bulk solidifying amorphous alloy is stabilized at a casting temperature such that the alloy is in a viscosity regime of 1 to 1,000 poise. 44. The apparatus of claim 36, wherein the bulk solidifying amorphous alloy is stabilized at a casting temperature such that the alloy is in a viscosity regime of 10 to 100 poise. 45. The apparatus of claim 36, wherein the solid amorphous alloy sheet has a thickness of 0.1 to 10 mm. 46. The apparatus of claim 36, wherein the solid amorphous alloy sheet has a thickness of 0.5 to 3 mm. 47. The apparatus of claim 40, wherein the alloy is introduced onto the casting body under pressure. 48. The apparatus of claim 36, wherein the alloy can be described as (Zr,Ti)a(Ni,Cu,Fe)b(Be,Al,Si,B)c, where a is in the range of from 30 to 75, b is in the range of from 5 to 60, and c in the range of from 0 to 50 in atomic percentages. 49. The apparatus of claim 36, wherein the alloy is ferrous metal based. 50. The apparatus of claim 36 wherein the alloy further comprises ductile crystalline phase precipitates.
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