Laser 3D Printing of Fe-Based Bulk Metallic Glass: Microstructure Evolution and Crack Propagation

This work presents a comprehensive study of microstructure evolution, crack development and hardness performance of Fe-based bulk metallic glass parts processed by laser 3D printing. The combination of a low scan speed and high energy density generates a low temperature gradient, leading to supercooling and the formation of coarse dendrite and cellular crystal microstructure. Columnar dendrites grow in a single direction with large stress, and cracks are easily formed between the dendrites. The stress intensity factor (SIF) caused by the crack surface tension is small, the crack healing effect is weak, and it is difficult to prevent crack propagation. Cellular grain growth is uniform and more easily accommodates the strain, preventing crack initiation and propagation. In contrast, use of a high scan speed with low energy input produces a fine and uniform dendrite or even nanocrystalline, microstructure with microcracks. The SIF caused by the crack surface tension is large, and the crack healing effect is strong and prevents crack initiation and propagation. For low energy density, the hardness of the sample is similar to the hardness of the cast amorphous. This result indicates that the printing sample retained some amorphous characteristics.