High-entropy metallic glasses (HEMGs) based on the ZrCuNiAlTa system have emerged as a groundbreaking class of materials due to their exceptional mechanical properties and thermal stability. Recent studies have demonstrated that these alloys exhibit a compressive strength exceeding 2.5 GPa and a Young’s modulus of ~110 GPa, making them ideal for high-stress structural applications. Advanced characterization techniques, such as synchrotron X-ray diffraction and transmission electron microscopy, have revealed that the unique amorphous structure of these alloys is stabilized by the synergistic effects of multiple principal elements, which hinder crystallization up to temperatures as high as 750°C. This thermal stability is critical for applications in aerospace and nuclear industries, where materials must withstand extreme environments. The latest breakthroughs include the development of a novel compositional design strategy that optimizes the atomic size mismatch and mixing enthalpy, resulting in a glass-forming ability (GFA) parameter (γ = Tx/(Tg + Tl)) of 0.42, one of the highest reported for HEMGs.
The fracture toughness of ZrCuNiAlTa-based HEMGs has been significantly enhanced through microstructural engineering, achieving values exceeding 80 MPa·m^1/2, which is unprecedented for metallic glasses. This improvement is attributed to the introduction of nanoscale heterogeneities within the amorphous matrix, which act as crack arrestors and promote energy dissipation during fracture. Recent in-situ mechanical testing combined with atomic force microscopy (AFM) has shown that these heterogeneities induce localized shear band multiplication, delaying catastrophic failure. Additionally, computational modeling using molecular dynamics simulations has provided insights into the atomic-scale mechanisms governing plasticity in these materials, revealing that the presence of Ta atoms enhances cross-slip events, further improving toughness. These findings pave the way for designing HEMGs with tailored fracture resistance for critical structural components.
The corrosion resistance of ZrCuNiAlTa HEMGs has been a focal point of recent research, with studies demonstrating exceptional performance in aggressive environments. Electrochemical testing in 3.5 wt.% NaCl solution revealed a corrosion current density (Icorr) as low as 0.12 µA/cm² and a passive film breakdown potential exceeding 1.2 V vs. SCE, outperforming conventional stainless steels and titanium alloys. The formation of a dense oxide layer rich in ZrO2 and Al2O3 has been identified as the key factor contributing to this superior corrosion resistance. Furthermore, advanced surface modification techniques, such as plasma electrolytic oxidation (PEO), have been employed to enhance the protective properties of this oxide layer, achieving a hardness increase from 6 GPa to 9 GPa while maintaining excellent adhesion to the substrate.
Recent advancements in additive manufacturing have enabled the fabrication of complex-shaped components from ZrCuNiAlTa HEMGs with minimal defects and retained amorphous structure. Laser powder bed fusion (LPBF) parameters optimized for this alloy system have resulted in parts with a relative density >99% and a glassy fraction >95%, as confirmed by differential scanning calorimetry (DSC). This breakthrough opens new avenues for lightweight structural applications in industries such as automotive and biomedical devices, where intricate geometries are often required.
The fatigue behavior of ZrCuNiAlTa HEMGs has been systematically investigated under cyclic loading conditions, revealing endurance limits exceeding 600 MPa at 10^7 cycles under tension-compression loading at room temperature. High-cycle fatigue testing combined with advanced imaging techniques has shown that fatigue cracks initiate at surface defects but propagate slowly due to the material’s inherent resistance to shear band formation. These results underscore the potential of ZrCuNiAlTa HEMGs for long-term structural applications where fatigue resistance is critical.
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