Building Zr-based metallic glass part on Ti-6Al-4V substrate by laser-foil-printing additive manufacturing

Abstract Through using Zr intermediate layers, Zr65.7Ti3.3Al3.7Ni11.7Cu15.6 metallic glass (MG) parts are successfully built on Ti-6Al-4V substrates by laser-foil-printing (LFP) additive manufacturing technology in which MG foils are laser welded layer-by-layer onto the substrate. The printed MG part is free of porosity, cracking and crystallization; additionally, its glass transition temperature, crystallization temperature, micro-hardness, and tensile strength are very similar to the original MG material. The Zr intermediate layers are aimed at preventing direct interaction between the first layer of MG foil and the Ti substrate; otherwise, the welded MG foils would peel off from the substrate due to the formation of hard and brittle intermetallic compounds. With the use of Zr intermediate layers, the bonding strength between the printed MG part and the Ti substrate can reach 758 MPa owing to the formation of α-Zr phase.