Impact of manufacturing method on the properties of bulk amorphous Zr35Ti30Be27.5Cu7.5 alloy

Zirconium-based bulk metallic glasses, such as Zr35Ti30Be27.5Cu7.5, exhibit outstanding strength, elasticity, and corrosion resistance, making them highly attractive for advanced engineering applications. However, producing bulk amorphous components remains challenging due to the high cooling rates required to prevent crystallization. In this study, Zr35Ti30Be27.5Cu7.5 alloys were fabricated using casting, joining sheet materials, direct energy deposition, and powder bed fusion. Comparative analysis of their structure, phase composition, density, and mechanical properties revealed the main features of the methods used. Castings suffer from structural inhomogeneities and lower density due to insufficient cooling in the ingot center, as well as defects. Joining sheet materials produces small, homogeneous amorphous regions (<5 mm) but faces challenges regarding density and scalability due to temperature control issues. Direct energy deposition enables the creation of larger compacts (>10 mm) with high amorphism and density; however, non-uniform crystallite distribution reduces mechanical properties. Powder bed fusion emerges as the optimal technology for producing high-quality, high-strength, and high-density Zr-based bulk metallic glass components, outperforming other methods in both material properties and manufacturing precision. Optimal conditions were identified, providing a pathway for scalable manufacturing of Zr-based bulk amorphous metallic alloys with superior properties.