In the realm of advanced materials, a groundbreaking study led by Régis Daniel Cava, has unveiled a novel method for producing bulk metallic glass (BMG) alloy strips using a process called spray rolling. This research, published in the journal ‘Materials Research’ (Materiais Pesquisa), could revolutionize the energy sector by offering a new approach to manufacturing materials with unique properties.
The study focused on an iron-based BMG alloy with a specific composition of Fe-35.2Co-4.3B-2.8Si-7.7Nb (wt.%). The goal was to achieve a fully amorphous structure, which is highly desirable for its superior mechanical properties and corrosion resistance. To estimate the cooling rate during the spray rolling process, the researchers also produced aluminum alloy samples using the same method. By analyzing the secondary dendritic arm spacing in the aluminum strips, they were able to calculate the cooling rate.
The spray rolling process involves atomizing the alloy onto copper rolls rotating at high speeds. In this case, the rolls were moving at 4.46 m/s, resulting in thin strips with a mean width of 150 mm and several centimeters in length. The cooling rate was evaluated to be approximately 105 K/s, which is crucial for obtaining the fully amorphous structure in the BMG alloy.
Cava explains, “The high cooling rate achieved through spray rolling is essential for preventing crystallization and ensuring the formation of a fully amorphous phase.” This breakthrough could have significant implications for the energy sector, where materials with high strength, corrosion resistance, and unique magnetic properties are in high demand.
The ability to produce BMG strips with these properties could lead to the development of more efficient and durable components for energy generation and storage systems. For instance, these materials could be used in the production of high-performance transformers, generators, and other electrical components, reducing energy losses and improving overall efficiency.
Moreover, the spray rolling process offers a scalable and cost-effective method for manufacturing BMG alloys, making it a viable option for industrial applications. As Cava notes, “The spray rolling process not only enables the production of fully amorphous BMG strips but also provides a pathway for large-scale manufacturing, which is crucial for commercialization.”
This research opens up new avenues for the development of advanced materials in the energy sector. By leveraging the unique properties of BMG alloys, researchers and engineers can create innovative solutions that address the challenges of energy efficiency, durability, and sustainability. The findings published in ‘Materials Research’ serve as a significant step forward in the field of materials science and engineering, paving the way for future developments in the energy sector.
