Seamless thermoplastic joining of ZrCu-based bulk metallic glasses via simple high-strain uniaxial compression
Abstract
Bulk metallic glasses (BMGs) exhibit exceptional physicochemical properties, but their applications remain limited by casting size constraints. Existing joining methods for BMGs face challenges, including crystallization risk, difficulties in control, and complex equipment requirements. Here we show a simple, scalable thermoplastic joining method for Zr-based BMGs using high-strain uniaxial compression within the supercooled liquid region. Using a precursor of Zr44Cu37Ag7Al7Be5 BMG with medium formability, we achieved successful macroscopic joining at 490 °C with strains of 30–70%. We show that microscopic joining quality increases with applied strain, resulting in metallic bonding and microstructural integrity with local chemical and mechanical uniformity at 70% strain. The proposed method exploits the unique homogeneous amorphous structure and viscous flow behavior of BMGs, enabling atomic-scale merging during deformation. This approach offers reliable control, reduced crystallization risks, and accommodation of complex geometries. The straightforward thermomechanical process requires standard heating-compression equipment, providing an effective solution to overcome BMG size restrictions and expand their practical applications in advanced systems requiring larger components.
Michał Biały
PhD Student
Amadeusz Łaszcz
Researcher
