An in vivo preclinical study assessing biocompatibility of Pd-based bulk metallic glass.

BACKGROUND: The bulk metallic glass (BMG), Pd79Ag3.5P6Si9.5Ge2, has a high fracture toughness and has been found to accommodate post-yield stress, unlike most other BMG. Moreover, due to its greater noble gas composition it has a intrinsic corrosion resistance, ideal for dental and orthopedic implants. OBJECTIVE: This present study aimed to evaluate the in vivo application of Pd79Ag3.5P6Si9.5Ge2 in a large translational sheep model to assess its efficacy to be utilized as an endosteal device. METHODS: Twelve implants in the form of cylindrical rods (3 mm in diameter) were produced through rapid quenching. Each sheep (n = 12) received one osteotomy in the mandibular region using rotary instrumentation, which was filled with Pd79Ag3.5P6Si9.5Ge2. After 6- and 24-weeks the animals were euthanized, and samples collected en bloc to conduct histomorphometric analysis. The degree of osseointegration were assessed through bone-to-implant contact (BIC). RESULTS: All samples revealed favorable BIC along with with fibrous connective tissue layers at both 6- and 24-weeks. Bone along with interfacial remodeling was observed in proximity with the metallic glass surface at 6 weeks with higher degrees of bone organization being observed at the later healing time, 24 weeks. CONCLUSIONS: The synthesized BMG, given its unique combination of toughness and strength, revealed potential to serve as an alternative to commonly used Ti alloys.

Designing color in metallic glass.

"Designing" metallic glasses to exhibit properties beyond those offered within the narrow composition ranges where glass formation is possible poses a formidable scientific challenge. This challenge may be tackled by forming composite structures comprising a metallic glass matrix and homogeneously precipitated dendrites, known as "metallic glass matrix composites" (MGMCs). In principle, MGMCs can be designed to exploit the attractive performance characteristics of the metallic glass while alleviating its negative undesirable attributes. In this work we introduce a MGMC development concept for designing color in metallic glass. MGMCs consisting of a white-gold metallic glass matrix with finely dispersed yellow-gold microdendrites are explored. A series of gold MGMCs is developed displaying uniform and visually-unresolved yellow colors over a broad range of chromaticity, along with high overall hardness. This design concept paves the way for the development of a new generation of metal alloys that combine advanced engineering performance with attractive cosmetic attributes.

Origin of embrittlement in metallic glasses.

Owing to their glassy nature, metallic glasses demonstrate a toughness that is extremely sensitive to the frozen-in configurational state. This sensitivity gives rise to "annealing embrittlement," which is often severe and in many respects limits the technological advancement of these materials. Here, equilibrium configurations (i.e., "inherent states") of a metallic glass are established around the glass transition, and the configurational properties along with the plane-strain fracture toughness are evaluated to associate the intrinsic glass toughness with the inherent state properties and identify the fundamental origin of embrittlement. The established correlations reveal a one-to-one correspondence between toughness and shear modulus continuous over a broad range of inherent states, suggesting that annealing embrittlement is controlled almost solely by an increasing resistance to shear flow. This annealing embrittlement sensitivity is shown to vary substantially between metallic glass compositions, and appears to correlate well with the fragility of the metallic glass.

How the toughness in metallic glasses depends on topological and chemical heterogeneity.

To gain insight into the large toughness variability observed between metallic glasses (MGs), we examine the origin of fracture toughness through bending experiments and molecular dynamics (MD) simulations for two binary MGs: Pd82Si18 and Cu46Zr54 The bending experiments show that Pd82Si18 is considerably tougher than Cu46Zr54, and the higher toughness of Pd82Si18 is attributed to an ability to deform plastically in the absence of crack nucleation through cavitation. The MD simulations study the initial stages of cavitation in both materials and extract the critical factors controlling cavitation. We find that for the tougher Pd82Si18, cavitation is governed by chemical inhomogeneity in addition to topological structures. In contrast, no such chemical correlations are observed in the more brittle Cu46Zr54, where topological low coordination number polyhedra are still observed around the critical cavity. As such, chemical inhomogeneity leads to more difficult cavitation initiation in Pd82Si18 than in Cu46Zr54, leading to a higher toughness. The absence of chemical separation during cavitation initiation in Cu46Zr54 decreases the energy barrier for a cavitation event, leading to lower toughness.

Shaping metallic glasses by electromagnetic pulsing.

With damage tolerance rivalling advanced engineering alloys and thermoplastic forming capabilities analogous to conventional plastics, metallic glasses are emerging as a modern engineering material. Here, we take advantage of their unique electrical and rheological properties along with the classic Lorentz force concept to demonstrate that electromagnetic coupling of electric current and a magnetic field can thermoplastically shape a metallic glass without conventional heating sources or applied mechanical forces. Specifically, we identify a process window where application of an electric current pulse in the presence of a normally directed magnetic field can ohmically heat a metallic glass to a softened state, while simultaneously inducing a large enough magnetic body force to plastically shape it. The heating and shaping is performed on millisecond timescales, effectively bypassing crystallization producing fully amorphous-shaped parts. This electromagnetic forming approach lays the groundwork for a versatile, time- and energy-efficient manufacturing platform for ultrastrong metals.

Accessing thermoplastic processing windows in metallic glasses using rapid capacitive discharge.

The ability of the rapid-capacitive discharge approach to access optimal viscosity ranges in metallic glasses for thermoplastic processing is explored. Using high-speed thermal imaging, the heating uniformity and stability against crystallization of Zr35Ti30Cu7.5Be27.5 metallic glass heated deeply into the supercooled region is investigated. The method enables homogeneous volumetric heating of bulk samples throughout the entire supercooled liquid region at high rates (~10(5) K/s) sufficient to bypass crystallization throughout. The crystallization onsets at temperatures in the vicinity of the "crystallization nose" were identified and a Time-Temperature-Transformation diagram is constructed, revealing a "critical heating rate" for the metallic glass of ~1000 K/s. Thermoplastic process windows in the optimal viscosity range of 10(0)-10(4) Pa · s are identified, being confined between the glass relaxation and the eutectic crystallization transition. Within this process window, near-net forging of a fine precision metallic glass part is demonstrated.

Compositional landscape for glass formation in metal alloys.

A high-resolution compositional map of glass-forming ability (GFA) in the Ni-Cr-Nb-P-B system is experimentally determined along various compositional planes. GFA is shown to be a piecewise continuous function formed by intersecting compositional subsurfaces, each associated with a nucleation pathway for a specific crystalline phase. Within each subsurface, GFA varies exponentially with composition, wheres exponential cusps in GFA are observed when crossing from one crystallization pathway to another. The overall GFA is shown to peak at multiple exponential hypercusps that are interconnected by ridges. At these compositions, quenching from the high-temperature melt yields glassy rods with diameters exceeding 1 cm, whereas for compositions far from these cusps the critical rod diameter drops precipitously and levels off to 1 to 2 mm. The compositional landscape of GFA is shown to arise primarily from an interplay between the thermodynamics and kinetics of crystal nucleation, or more precisely, from a competition between driving force for crystallization and liquid fragility.

Enhanced fatigue endurance of metallic glasses through a staircase-like fracture mechanism.

Bulk-metallic glasses (BMGs) are now candidate materials for structural applications due to their exceptional strength and toughness. However, their fatigue resistance can be poor and inconsistent, severely limiting their potential as reliable structural materials. As fatigue limits are invariably governed by the local arrest of microscopically small cracks at microstructural features, the lack of microstructure in monolithic glasses, often coupled with other factors, such as the ease of crack formation in shear bands or a high susceptibility to corrosion, can lead to low fatigue limits (some ~1/20 of their tensile strengths) and highly variable fatigue lives. BMG-matrix composites can provide a solution here as their duplex microstructures can arrest shear bands at a second phase to prevent cracks from exceeding critical size; under these conditions, fatigue limits become comparable with those of crystalline alloys. Here, we report on a Pd-based glass that similarly has high fatigue resistance but without a second phase. This monolithic glass displays high intrinsic toughness from extensive shear-band proliferation with cavitation and cracking effectively obstructed. We find that this property can further promote fatigue resistance through extrinsic crack-tip shielding, a mechanism well known in crystalline metals but not previously reported in BMGs, whereby cyclically loaded cracks propagate in a highly "zig-zag" manner, creating a rough "staircase-like" profile. The resulting crack-surface contact (roughness-induced crack closure) elevates fatigue properties to those comparable to crystalline alloys, and the accompanying plasticity helps to reduce flaw sensitivity in the glass, thereby promoting structural reliability.

Predicted Optimum Composition for the Glass-Forming Ability of Bulk Amorphous Alloys: Application to Cu-Zr-Al.

Metallic glasses have been established to have unique properties such as ductility, toughness, and soft magnetism with promising engineering applications. However, the glass-forming ability (GFA) has not been sufficient to synthesize the bulk metallic glasses (BMGs) required for many engineering applications. Attempts to develop the understanding of the GFA required to predict the optimum alloys have not yet been proven successful. We develop here a computational model based on molecular dynamics simulations that explains the dramatic change of GFA with alloying small amounts of Al into Cu-Zr. We find that the high GFA to form BMGs depends on a combination of three factors, (a) a low thermodynamic driving force for crystallization, (b) a high melt viscosity, and (c) large ratios of icosahedral structures in the liquid phase. These computational methods to predict these factors that suppress formation of crystal nuclei and slow the dynamic motions in the liquids are practical for in silico prediction of new alloys with optimal GFA.

Beating crystallization in glass-forming metals by millisecond heating and processing.

The development of metal alloys that form glasses at modest cooling rates has stimulated broad scientific and technological interest. However, intervening crystallization of the liquid in even the most robust bulk metallic glass-formers is orders of magnitude faster than in many common polymers and silicate glass-forming liquids. Crystallization limits experimental studies of the undercooled liquid and hampers efforts to plastically process metallic glasses. We have developed a method to rapidly and uniformly heat a metallic glass at rates of 10(6) kelvin per second to temperatures spanning the undercooled liquid region. Liquid properties are subsequently measured on millisecond time scales at previously inaccessible temperatures under near-adiabatic conditions. Rapid thermoplastic forming of the undercooled liquid into complex net shapes is implemented under rheological conditions typically used in molding of plastics. By operating in the millisecond regime, we are able to "beat" the intervening crystallization and successfully process even marginal glass-forming alloys with very limited stability against crystallization that are not processable by conventional heating.

A damage-tolerant glass.

Owing to a lack of microstructure, glassy materials are inherently strong but brittle, and often demonstrate extreme sensitivity to flaws. Accordingly, their macroscopic failure is often not initiated by plastic yielding, and almost always terminated by brittle fracture. Unlike conventional brittle glasses, metallic glasses are generally capable of limited plastic yielding by shear-band sliding in the presence of a flaw, and thus exhibit toughness-strength relationships that lie between those of brittle ceramics and marginally tough metals. Here, a bulk glassy palladium alloy is introduced, demonstrating an unusual capacity for shielding an opening crack accommodated by an extensive shear-band sliding process, which promotes a fracture toughness comparable to those of the toughest materials known. This result demonstrates that the combination of toughness and strength (that is, damage tolerance) accessible to amorphous materials extends beyond the benchmark ranges established by the toughest and strongest materials known, thereby pushing the envelope of damage tolerance accessible to a structural metal.

Atomistic Characterization of Stochastic Cavitation of a Binary Metallic Liquid under Negative Pressure.

We demonstrate the stochastic nature of cavitation in a binary metallic liquid Cu46Zr54 during hydrostatic expansion by employing molecular dynamics (MD) simulations using a quantum mechanics (QM)-derived potential. The activation volume is obtained from MD simulations and transition-state theory. Extrapolation of the pressure dependence of the activation volume from our MD simulations to low tensile pressure agrees remarkably with macroscale cavitation experiments. We find that classical nucleation theory can predict the cavitation rate if we incorporate the Tolman length derived from the MD simulations.

Development of tough, low-density titanium-based bulk metallic glass matrix composites with tensile ductility.

The mechanical properties of bulk metallic glasses (BMGs) and their composites have been under intense investigation for many years, owing to their unique combination of high strength and elastic limit. However, because of their highly localized deformation mechanism, BMGs are typically considered to be brittle materials and are not suitable for structural applications. Recently, highly-toughened BMG composites have been created in a Zr-Ti-based system with mechanical properties comparable with high-performance crystalline alloys. In this work, we present a series of low-density, Ti-based BMG composites with combinations of high strength, tensile ductility, and excellent fracture toughness.

Stochastic metallic-glass cellular structures exhibiting benchmark strength.

By identifying the key characteristic "structural scales" that dictate the resistance of a porous metallic glass against buckling and fracture, stochastic highly porous metallic-glass structures are designed capable of yielding plastically and inheriting the high plastic yield strength of the amorphous metal. The strengths attainable by the present foams appear to equal or exceed those by highly engineered metal foams such as Ti-6Al-4V or ferrous-metal foams at comparable levels of porosity, placing the present metallic-glass foams among the strongest foams known to date.

Designing metallic glass matrix composites with high toughness and tensile ductility.

The selection and design of modern high-performance structural engineering materials is driven by optimizing combinations of mechanical properties such as strength, ductility, toughness, elasticity and requirements for predictable and graceful (non-catastrophic) failure in service. Highly processable bulk metallic glasses (BMGs) are a new class of engineering materials and have attracted significant technological interest. Although many BMGs exhibit high strength and show substantial fracture toughness, they lack ductility and fail in an apparently brittle manner in unconstrained loading geometries. For instance, some BMGs exhibit significant plastic deformation in compression or bending tests, but all exhibit negligible plasticity (<0.5% strain) in uniaxial tension. To overcome brittle failure in tension, BMG-matrix composites have been introduced. The inhomogeneous microstructure with isolated dendrites in a BMG matrix stabilizes the glass against the catastrophic failure associated with unlimited extension of a shear band and results in enhanced global plasticity and more graceful failure. Tensile strengths of approximately 1 GPa, tensile ductility of approximately 2-3 per cent, and an enhanced mode I fracture toughness of K(1C) approximately 40 MPa m(1/2) were reported. Building on this approach, we have developed 'designed composites' by matching fundamental mechanical and microstructural length scales. Here, we report titanium-zirconium-based BMG composites with room-temperature tensile ductility exceeding 10 per cent, yield strengths of 1.2-1.5 GPa, K(1C) up to approximately 170 MPa m(1/2), and fracture energies for crack propagation as high as G(1C) approximately 340 kJ m(-2). The K(1C) and G(1C) values equal or surpass those achievable in the toughest titanium or steel alloys, placing BMG composites among the toughest known materials.

Anelastic to plastic transition in metallic glass-forming liquids.

The configurational properties associated with the transition from anelasticity to plasticity in a transiently deforming metallic glass-forming liquid are studied. The data reveal that the underlying transition kinetics for flow can be separated into reversible and irreversible configurational hopping across the liquid energy landscape, identified with beta and alpha relaxation processes, respectively. A critical stress characterizing the transition is recognized as an effective Eshelby "backstress," revealing a link between the apparent anelasticity and the "confinement stress" of the elastic matrix surrounding the plastic core of a shear transformation zone.

Cooperative shear model for the rheology of glass-forming metallic liquids.

A rheological law based on the concept of cooperatively sheared flow zones is presented, in which the effective thermodynamic state variable controlling flow is identified to be the isoconfigurational shear modulus of the liquid. The law captures Newtonian as well as non-Newtonian viscosity data for glass-forming metallic liquids over a broad range of fragility. Acoustic measurements on specimens deformed at a constant strain rate correlate well with the measured steady-state viscosities, hence verifying that viscosity has a unique functional relationship with the isoconfigurational shear modulus.