Alloying technique for fe-based bulk amorphous alloy

Abstract

One embodiment provides a method of making an alloy feedstock, comprising: forming a first composition by combining Fe with a first nonmetal element; forming a second composition by combining Fe with a plurality of transition metal elements; forming a third composition by combining the second composition with a second nonmetal element; and combining the first composition with the third composition to form an alloy feedstock.

What is claimed: 
     
         1 . A method of making an alloy feedstock, comprising:
 forming a first composition by combining Fe element with a first nonmetal element;   forming a second composition by combining Fe element with a plurality of transition metal elements;   forming a third composition by combining the second composition with a second nonmetal element; and   alloying the first composition with the third composition to form an alloy feedstock.   
     
     
         2 . The method of  claim 1 , wherein the first nonmetal element is B, P, Si, Ge, C, or combinations thereof. 
     
     
         3 . The method of  claim 1 , wherein the plurality of transition metal elements comprises Mo, Cr, Ni, Y, Co, Mn, Ga, Er, or combinations thereof. 
     
     
         4 . The method of  claim 1 , wherein at least one of the first nonmetal element and the second nonmetal element is a metalloid. 
     
     
         5 . The method of  claim 1 , wherein the second nonmetal element is Si, C, or both. 
     
     
         6 . The method of  claim 1 , wherein at the beginning of the forming the third composition the second nonmetal element is located under the second composition. 
     
     
         7 . The method of  claim 1 , wherein at least some of the elements have at least one dimension that is at least about 1 mm 
     
     
         8 . The method of  claim 1 , wherein the alloy feedstock is at least one of (i) homogeneous and (ii) not fully amorphous. 
     
     
         9 . The method of  claim 1 , wherein the alloy feedstock has a chemical formula of Fe 48 Cr 15 Mo 14 C 15 B 6 Y 2 . 
     
     
         10 . The method of  claim 1 , wherein at least a portion of the making involves arc melting. 
     
     
         11 . A method of making an alloy feedstock, comprising:
 forming a first composition by combining Fe with a first nonmetal element;   forming a carbon-containing composition by combining Fe with a plurality of transition metal elements and C;   alloying the first composition with the carbon-containing composition to form an alloy feedstock.   
     
     
         12 . The method of  claim 1 , wherein the forming a carbon-containing composition further comprising forming a second composition comprising Mo, Cr, Y, Ni, or combinations thereof, before forming the carbon-containing composition. 
     
     
         13 . The method of  claim 1 , wherein the forming a carbon-containing composition further comprising forming a second composition by melting an alloy stack having a stack order of Mo disposed over Fe, which is disposed over Cr, which is disposed over Y. 
     
     
         14 . The method of  claim 13 , wherein the forming has a lower evaporation of at least one of Fe and Cr for the second composition relative to a composition not with the stack order. 
     
     
         15 . The method of  claim 11 , wherein the first composition comprises an intermetallic compound. 
     
     
         16 . The method of  claim 11 , wherein the alloy feedstock is substantially crystalline. 
     
     
         17 . The method of  claim 11 , wherein the alloy feedstock has at least one dimension of at least 2 inches. 
     
     
         18 . The method of  claim 11 , further comprising making the alloy feedstock into a bulk amorphous alloy. 
     
     
         19 . The method of  claim 11 , wherein at least some of the elements used in the making are not in powder form. 
     
     
         20 . The method of  claim 11 , wherein the first nonmetal element is B. 
     
     
         21 . A method of making an alloy feedstock, comprising:
 providing a Fe-containing first composition;   combining C with a second composition comprising Mo, Cr, and Y to form a third composition; and   combining the first composition with the third composition to form an alloy feedstock.   
     
     
         22 . The method of  claim 21 , wherein the first composition is iron boride. 
     
     
         23 . The method of  claim 21 , wherein the second composition has a stack order of Mo disposed over Fe, which is disposed over Cr, which is disposed over Y. 
     
     
         24 . The method of  claim 21 , wherein the alloy feedstock has a weight of at least 100 g and at least one dimension of at least 2 inches. 
     
     
         25 . An alloy comprising:
 a first composition comprising Fe and a first nonmetal element;   a second composition comprising Fe, plurality of transition metal elements and a second nonmetal element;   wherein the first composition is alloyed with the second composition in the alloy.   
     
     
         26 . The alloy of  claim 25 , wherein the first nonmetal element is B, P, Si, Ge, C, or combinations thereof. 
     
     
         27 . The alloy of  claim 25 , wherein the plurality of transition metal elements comprises Mo, Cr, Ni, Y, Co, Mn, Ga, Er, or combinations thereof. 
     
     
         28 . The alloy of  claim 25 , wherein at least one of the first nonmetal element and the second nonmetal element is a metalloid. 
     
     
         29 . The alloy of  claim 25 , wherein the second nonmetal element is Si, C, or both. 
     
     
         30 . The alloy of  claim 25 , wherein at the beginning of the forming the third composition the second nonmetal element is located under the second composition. 
     
     
         31 . The alloy of  claim 25 , wherein at least some of the elements have at least one dimension that is at least about 1 mm 
     
     
         32 . The alloy of  claim 25 , wherein the alloy is at least one of (i) homogeneous and (ii) not fully amorphous. 
     
     
         33 . The alloy of  claim 25 , wherein the alloy has a chemical formula of Fe 48 Cr 15 Mo 14 C 15 B 6 Y 2 . 
     
     
         34 . The alloy of  claim 25 , wherein at least a portion of the making involves arc melting. 
     
     
         35 . The alloy of  claim 25 , wherein the second composition comprises a carbon-containing composition comprising C. 
     
     
         36 . The alloy of  claim 25 , wherein the second composition further comprises Mo, Cr, Y, Ni. 
     
     
         37 . The alloy of  claim 36 , wherein the second composition comprises a stack order of Mo disposed over Fe, which is disposed over Cr, which is disposed over Y. 
     
     
         38 . The alloy of  claim 25 , wherein the first composition comprises an intermetallic compound. 
     
     
         39 . The alloy of  claim 25 , wherein the alloy is substantially crystalline. 
     
     
         40 . The alloy of  claim 25 , wherein the alloy has at least one dimension of at least 2 inches. 
     
     
         41 . The alloy of  claim 25 , wherein the alloy comprises a bulk amorphous alloy.