Forming complex geometries using the casting process is a big challenge for bulk metallic glasses (BMGs), because of a lack of time of the window for shaping under the required high cooling rate. In this work, we open an approach named the “entire process vacuum high pressure die casting” (EPV-HPDC), which delivers the ability to fill die with molten metal in milliseconds, and create solidification under high pressure. Based on this process, various Zr-based BMGs were prepared by using industrial grade raw material. The results indicate that the EPV-HPDC process is feasible to produce a glassy structure for most Zr-based BMGs, with a size of 3 mm × 10 mm and with a high strength. In addition, it has been found that EPV-HPDC process allows complex industrial BMG parts, some of which are hard to be formed by any other metal processes, to be net shaped precisely. The BMG components prepared by the EVP-HPDC process possess the advantages of dimensional accuracy, efficiency, and cost compared with the ones formed by other methods. The EVP-HPDC process paves the way for the large-scale application of BMGs.

In this study, graphene-oxide (GO)-reinforced Ti–Al–Sn–Zr–Mo–Nb–Si high-temperature titanium-alloy-matrix composites were fabricated by powder metallurgy. The mixed powders with well-dispersed GO sheets were obtained by temperature-controlled solution mixing, in which GO sheets adsorb on the surface of titanium alloy particles. Vacuum deoxygenating was applied to remove the oxygen-containing groups in GO, in order to reduce the introduction of oxygen. The compact composites with refined equiaxed and lamellar α phase structures were prepared by hot isostatic pressing (HIP). The results show that in-situ TiC layers form on the surface of GO and GO promotes the precipitation of hexagonal (TiZr)₆Si₃ particles. The composites exhibit significant improvement in strength and microhardness. The room-temperature tensile strength, yield strength and microhardness of the composite added with 0.3 wt% GO are 9%, 15% and 27% higher than the matrix titanium alloy without GO, respectively, and the tensile strength and yield strength at 600 °C are 3% and 21% higher than the matrix alloy. The quantitative analysis indicates that the main strengthening mechanisms are load transfer strengthening, grain refinement and (TiZr)₆Si₃ second phase strengthening, which accounted for 48%, 30% and 16% of the improvement of room-temperature yield strength, respectively.

Non-isothermal oxidation is one of the important issues related to the safe application of high-temperature titanium alloys, so this study focuses on the non-isothermal oxidation behavior and mechanism of near-α titanium alloys. The thermogravimetry-differential scanning calorimetry (TGA/DSC) method was used to study the non-isothermal oxidation behavior of TA29 titanium alloy heated from room temperature to 1450 °C at a heating rate of 40 °C/min under pure oxygen atmosphere. The results show that non-isothermal oxidation behavior can be divided into five stages, including no oxidation, slow oxidation, accelerated oxidation, severe oxidation and deceleration oxidation; for the three-layer TiO₂ scale, Zr, Nb, Ta are enriched in the intermediate layer, while Al is rich in the inner layer and Sn is segregated at the oxide-substrate interface, which is related to their diffusion rates in the subsurface α case. The oxidation mechanism for each stage is: oxygen barrier effect of a thin compact oxide film; oxygen dissolution; lattice transformation accelerating the dissolution and diffusion of oxygen; oxide formation; oxygen barrier effect of recrystallization and sintering microstructure in outer oxide scale. The alloying elements with high valence state and high diffusion rate in α-Ti are favorable to slow down the oxidation rate at the stage governed by oxide formation.

Non-isothermal oxidation is one of the important issues for the safe application of Ti-Al alloys, so this study aimed to illustrate the non-isothermal oxidation behaviors and the corresponding mechanisms of a TiAl-based alloy in comparison with a Ti₃Al-based alloy. The non-isothermal oxidation behaviors of Ti-46Al-2Cr-5Nb and Ti-24Al-15Nb-1.5Mo alloys in pure oxygen were comparatively investigated with a thermogravimetry-differential scanning calorimetry (TGA/DSC) simultaneous thermal analyzer heating from room temperature to 1450 °C with a heating rate of 40 °C/min. When the temperature rose above 1280 °C, the oxidation rate of the Ti-46Al-2Cr-5Nb alloy sharply increased and exceeded that of the Ti-24Al-15Nb-1.5Mo alloy owing to the occurrence of internal oxidation. When the temperature was higher than 1350 °C, the oxidation rate of the Ti-46Al-2Cr-5Nb alloy decreased obviously due to the generation of an oxygen-barrier β-Al₂TiO₅-rich layer by a chemical reaction between Al₂O₃ and TiO₂ in the oxide scale. Based on Wagner’s theory of internal oxidation, the reason for the occurrence of internal oxidation in the Ti-46Al-2Cr-5Nb alloy is the formation of the α phase in the subsurface, while no internal oxidation occurred in the Ti-24Al-15Nb-1.5Mo alloy due to the existence of the β phase in the subsurface with the enrichment of Nb and Mo.

The exploration of microstructures in high temperature alloy melts is important for manufacturing of metallic components but extremely challenging. Here, we report experimental evidence of the disruption of Si-rich microstructure in engineering-lightweight Al–12.2at.%Si alloy melt at 1100 °C, via melt-spinning (MS) of Al_1−xSi_x (x = 0.03,0.07,0.122,0.2) alloy melts from different initial melt temperatures, 800 °C and 1100 °C, under the super-high cooling rate of ~ 10⁶ °C/s, in cooperation with the small angle neutron scattering (SANS) measurement. Si particles in 1100 °C MS alloys are abnormally smaller and increased in number at Al–12.2at.%Si, compared with 800 °C MS alloys, which demonstrates the disruption of Si-rich microstructure in Al–12.2at.%Si alloy melt at 1100 °C. SANS experiment verifies that large quantities of small (0–10 nm) Si-rich microstructures and small quantities of large (10–240 nm) Si-rich microstructures exist in Al–12.2at.%Si alloy melt, and the large Si-rich microstructures disrupt into small Si-rich microstructures with increasing of melt temperature from 800 to 1100 °C. Microstructure analysis of the MS alloys indicates that the large Si-rich microstructures in Al–12.2at.%Si alloy melt are probably aggregates comprising multiple small Si-rich microstructures. This work also provides a pathway for the exploration of microstructures in other high temperature alloy melts.