A novel approach hybridizing lithography-pressureless sintering additive manufacturing to go beyond the critical casting size limit of Fe-based bulk metallic glass.
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| Title: | A novel approach hybridizing lithography-pressureless sintering additive manufacturing to go beyond the critical casting size limit of Fe-based bulk metallic glass. |
|---|---|
| Authors: | Ibrahim, Mahmoud Z.1,2 (AUTHOR) mahmoudzakaria@um.edu.my, Gierl-Mayer, Christian3 (AUTHOR), Harakaly, Gyoergy4 (AUTHOR), Mitteramskogler, Gerald4 (AUTHOR), Kuo, Tsung-Yuan5 (AUTHOR), Chen, Kuan-Wei6 (AUTHOR), Sarhan, Ahmed A.D.7,8 (AUTHOR), Yusof, Farazila1,2 (AUTHOR) |
| Source: | International Journal of Advanced Manufacturing Technology. Jun2026, Vol. 144 Issue 7/8, p5389-5399. 11p. |
| Subjects: | Metallic glasses, Sintering, Amorphous substances, Photolithography, Mechanical behavior of materials, Three-dimensional printing |
| Abstract: | Fe-based bulk metallic glasses (BMGs) have high potential to be applied in biomedical devices, automotive and aerospace, and sports equipment due to their exceptional mechanical, physical and chemical properties. However, they have low glass forming ability (GFA) and high tendency to crack during solidification, restricting its critical casting size to a few millimeters which represents the bottleneck for broader industrial-scale utilization. Metal Additive Manufacturing (MAM) is a promising strategy to fabricate BMGs with larger sizes and complex geometries, bypassing the current bottleneck. Nevertheless, the fusion-based-AM techniques such as selective laser melting (SLM) trigger crystallization of the amorphous structure due to high thermal input. Sinter-based MAM is another strategy that decouples shaping and consolidation, preventing cracking and ability to process difficult-to-print materials. Lithography MAM (LMAM) offers exceptional surface quality, dimensional accuracy, and ability to process fine powders. Hence, this research proposes a novel approach hybridizing LMAM and pressure-less sintering approach to fabricate high-precision, complex, and dense monolithic Fe-based bulk metallic glass (BMG) components, achieving maximum amorphous content and exceeding the critical casting thickness limitations. The sample achieved a relative density of 65.934% with high amorphous content (87.45%) at 800 °C for 180 min. While the sample sintered at 660 °C with high heating rate (30 °C/min) for 120 min achieved relative density 65.456% and 90.60% amorphous content. SEM examination confirmed inter-particles diffusion, resulting in a modulus of rupture (MOR) of 4.1–7.9 MPa. These findings highlight the potential of utilizing LMAM to overcome the limited critical casting thickness of Fe-based BMG and maintain the high amorphous content. [ABSTRACT FROM AUTHOR] |
| Copyright of International Journal of Advanced Manufacturing Technology is the property of Springer Nature and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract. (Copyright applies to all Abstracts.) | |
| Database: | Engineering Source |
| FullText | Text: Availability: 0 |
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| Header | DbId: egs DbLabel: Engineering Source An: 194545574 AccessLevel: 6 PubType: Academic Journal PubTypeId: academicJournal PreciseRelevancyScore: 0 |
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| Items | – Name: Title Label: Title Group: Ti Data: A novel approach hybridizing lithography-pressureless sintering additive manufacturing to go beyond the critical casting size limit of Fe-based bulk metallic glass. – Name: Author Label: Authors Group: Au Data: <searchLink fieldCode="AR" term="%22Ibrahim%2C+Mahmoud+Z%2E%22">Ibrahim, Mahmoud Z.</searchLink><relatesTo>1,2</relatesTo> (AUTHOR)<i> mahmoudzakaria@um.edu.my</i><br /><searchLink fieldCode="AR" term="%22Gierl-Mayer%2C+Christian%22">Gierl-Mayer, Christian</searchLink><relatesTo>3</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Harakaly%2C+Gyoergy%22">Harakaly, Gyoergy</searchLink><relatesTo>4</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Mitteramskogler%2C+Gerald%22">Mitteramskogler, Gerald</searchLink><relatesTo>4</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Kuo%2C+Tsung-Yuan%22">Kuo, Tsung-Yuan</searchLink><relatesTo>5</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Chen%2C+Kuan-Wei%22">Chen, Kuan-Wei</searchLink><relatesTo>6</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Sarhan%2C+Ahmed+A%2ED%2E%22">Sarhan, Ahmed A.D.</searchLink><relatesTo>7,8</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Yusof%2C+Farazila%22">Yusof, Farazila</searchLink><relatesTo>1,2</relatesTo> (AUTHOR) – Name: TitleSource Label: Source Group: Src Data: <searchLink fieldCode="JN" term="%22International+Journal+of+Advanced+Manufacturing+Technology%22">International Journal of Advanced Manufacturing Technology</searchLink>. Jun2026, Vol. 144 Issue 7/8, p5389-5399. 11p. – Name: Subject Label: Subjects Group: Su Data: <searchLink fieldCode="DE" term="%22Metallic+glasses%22">Metallic glasses</searchLink><br /><searchLink fieldCode="DE" term="%22Sintering%22">Sintering</searchLink><br /><searchLink fieldCode="DE" term="%22Amorphous+substances%22">Amorphous substances</searchLink><br /><searchLink fieldCode="DE" term="%22Photolithography%22">Photolithography</searchLink><br /><searchLink fieldCode="DE" term="%22Mechanical+behavior+of+materials%22">Mechanical behavior of materials</searchLink><br /><searchLink fieldCode="DE" term="%22Three-dimensional+printing%22">Three-dimensional printing</searchLink> – Name: Abstract Label: Abstract Group: Ab Data: Fe-based bulk metallic glasses (BMGs) have high potential to be applied in biomedical devices, automotive and aerospace, and sports equipment due to their exceptional mechanical, physical and chemical properties. However, they have low glass forming ability (GFA) and high tendency to crack during solidification, restricting its critical casting size to a few millimeters which represents the bottleneck for broader industrial-scale utilization. Metal Additive Manufacturing (MAM) is a promising strategy to fabricate BMGs with larger sizes and complex geometries, bypassing the current bottleneck. Nevertheless, the fusion-based-AM techniques such as selective laser melting (SLM) trigger crystallization of the amorphous structure due to high thermal input. Sinter-based MAM is another strategy that decouples shaping and consolidation, preventing cracking and ability to process difficult-to-print materials. Lithography MAM (LMAM) offers exceptional surface quality, dimensional accuracy, and ability to process fine powders. Hence, this research proposes a novel approach hybridizing LMAM and pressure-less sintering approach to fabricate high-precision, complex, and dense monolithic Fe-based bulk metallic glass (BMG) components, achieving maximum amorphous content and exceeding the critical casting thickness limitations. The sample achieved a relative density of 65.934% with high amorphous content (87.45%) at 800 °C for 180 min. While the sample sintered at 660 °C with high heating rate (30 °C/min) for 120 min achieved relative density 65.456% and 90.60% amorphous content. SEM examination confirmed inter-particles diffusion, resulting in a modulus of rupture (MOR) of 4.1–7.9 MPa. These findings highlight the potential of utilizing LMAM to overcome the limited critical casting thickness of Fe-based BMG and maintain the high amorphous content. [ABSTRACT FROM AUTHOR] – Name: AbstractSuppliedCopyright Label: Group: Ab Data: <i>Copyright of International Journal of Advanced Manufacturing Technology is the property of Springer Nature and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract.</i> (Copyright applies to all Abstracts.) |
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| RecordInfo | BibRecord: BibEntity: Identifiers: – Type: doi Value: 10.1007/s00170-026-18186-3 Languages: – Code: eng Text: English PhysicalDescription: Pagination: PageCount: 11 StartPage: 5389 Subjects: – SubjectFull: Metallic glasses Type: general – SubjectFull: Sintering Type: general – SubjectFull: Amorphous substances Type: general – SubjectFull: Photolithography Type: general – SubjectFull: Mechanical behavior of materials Type: general – SubjectFull: Three-dimensional printing Type: general Titles: – TitleFull: A novel approach hybridizing lithography-pressureless sintering additive manufacturing to go beyond the critical casting size limit of Fe-based bulk metallic glass. Type: main BibRelationships: HasContributorRelationships: – PersonEntity: Name: NameFull: Ibrahim, Mahmoud Z. – PersonEntity: Name: NameFull: Gierl-Mayer, Christian – PersonEntity: Name: NameFull: Harakaly, Gyoergy – PersonEntity: Name: NameFull: Mitteramskogler, Gerald – PersonEntity: Name: NameFull: Kuo, Tsung-Yuan – PersonEntity: Name: NameFull: Chen, Kuan-Wei – PersonEntity: Name: NameFull: Sarhan, Ahmed A.D. – PersonEntity: Name: NameFull: Yusof, Farazila IsPartOfRelationships: – BibEntity: Dates: – D: 01 M: 06 Text: Jun2026 Type: published Y: 2026 Identifiers: – Type: issn-print Value: 02683768 Numbering: – Type: volume Value: 144 – Type: issue Value: 7/8 Titles: – TitleFull: International Journal of Advanced Manufacturing Technology Type: main |
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