Development of Bulk Metallic Glass Matrix Composites (BMGMC) by Additive Manufacturing: Modelling and Simulation – A Review: Part A

Bulk metallic glasses (BMGs) and their composites (BMGMC) have emerged as competitive materials for structural engineering applications exhibiting superior tensile strength, hardness along with very high elastic strain limit. However, they suffer from a lack of ductility and subsequent low toughness due to the inherent brittleness of the glassy structure which render them to failure without appreciable yielding owing to mechanisms of rapid movement of shear bands all throughout the volume of the material. This severely limits their use in fabricating structural and machinery parts. Various mechanisms have been proposed to counter this effect. Introduction of secondary ductile phase in the form of in-situ nucleating and growing dendrites from melt during solidification have proved out to be best solution of this problem. Nucleation and growth of these ductile phases have been extensively studied over the last 16 years since their introduction for the first time in Zr-based BMGMC by Prof. Johnson at Caltech. Data about almost all types of phases appearing in different systems have been successfully reported. However, there is very little information available about the precise mechanism underlying their nucleation and growth during solidification in a copper mould during conventional vacuum casting and melt pool of additively manufactured parts. Various routes have been proposed to study this including experiments in microgravity, levitation in synchrotron light and modelling and simulation. In this report consisting of two parts which is a preamble of author’s PhD Project, a concise review about evolution of microstructure in BMGMC during additive manufacturing have been presented with the aim to address fundamental problem of lack in ductility along with prediction of grain size and phase evolution with the help of advanced modelling and simulation techniques. It has been systematically proposed that 2 and 3 dimensional cellular automaton method combined with finite element (CAFE) tools programmed on MATLAB® and simulated on Ansys® would best be able to describe this phenomenon in most efficient way. Present part consists of general introduction of bulk metallic glass matrix composites (BMGMC), problem of lack of ductility in them, measures to counter it, success stories and their additive manufacturing.