Fabrication of bulk amorphous alloys by powder consolidation

The first successful synthesis of glassy alloy compacts with full strength by warm extrusion of atomized glassy powder in the supercooled liquid state is reported. The effects of powder processing and the extrusion conditions on the mechanical properties of the compacts were investigated for amorphous Zr₆₅Al₁₀Ni₁₀Cu₁₅ with a wide supercooled liquid region of 105K. The tensile strength and Young's modulus of the amorphous powder compacts were 1520MPa and 80GPa, respectively, which are similar to valves obtained in the as-cast bulk alloy and melt-spun ribbon. The high tensile strength is attributed to full densification, perfect bonding between powder particles and retention of ductility by extrusion at extrusion ratios above 4 in the supercooled liquid state. Powder processing, improved particle bonding, resulting in high strength at smaller extrusion ratios. The results of this study have major implications regarding the future development of bulk amorphous and nanocrystalline materials with complex shapes and novel properties.