# US 2022/0161319 A1 · Injection-molding device and method for manufacturing parts made of metallic glass > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2022/0161319 A1 - Document ID: US20220161319A1 - Status: Published application - Kind: A1 - Application number: 17/415,992 - Filed: 2019-12-20 - Published: 2022-05-26 - Earliest claimed: 2018-12-20 - Assignees: Vulkam - Applicants: Vulkam - Inventors: Xavier CERUTTI; Sebastien GRAVIER - Web page: https://patentgrep.com/patent/US20220161319A1 ## CPC - B22D 29/002: {by leaching, washing or dissolving} - C22C 33/003: {making amorphous alloys} - B22C 1/00: Compositions of refractory mould or core materials; Grain structures thereof (refractory materials in general C04B35/00); Chemical or physical features in the formation or manufacture of moulds - B22D 17/10: with horizontal press motion - B22D 17/22: Dies (manufacture, see the appropriate class, e.g. B23P15/24); Die plates; Die supports; Cooling equipment for dies; Accessories for loosening and ejecting castings from dies - C22C 1/11: Making amorphous alloys - C22C 45/00: Amorphous alloys (making amorphous non-ferrous alloys C22C1/11) - B22D: CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES (shaping of plastics or substances in a plastic state B29C; metallurgical processing, selection of substances to be added to metal C21, C22) - C22C: ALLOYS (treatment of alloys C21D, C22F) - B22C: FOUNDRY MOULDING (moulding refractory materials in general B28B) ## Abstract Device and method for injection moulding a metal alloy intended for manufacturing at least one part made of an amorphous metal alloy or metallic glass, wherein: an injection mould (2) delimits a cavity that has a receiving face (4) and a frontal moulding face (5) opposite the receiving face, at least one sacrificial shaping insert (7) is placed in said cavity and has a rear face (8), at least one contact zone of which is adjacent to at least one contact zone of said receiving face of the cavity and a front face (9) that is situated opposite said moulding face of the mould and provided with a recessed shape, and an injection piston (I I) is movable in a chamber (12) of the mould and communicates with the moulding impression. ## Claims ### Claim 1 A device for injection molding a metallic alloy, intended for manufacturing at least one part comprising an amorphous metallic alloy, said device comprising: an injection mold delimiting a cavity that has a receiving face and a frontal molding face opposite the receiving face, at least one sacrificial insert, placed in said cavity and having a rear face, at least one contact zone of which is adjacent to at least one contact zone of said receiving face of the cavity and a front face located opposite said molding face of the mold and provided with a recessed shape, a molding impression corresponding to space left free in the cavity comprising the sacrificial insert, and an injection piston movable in a chamber of the mold, which communicates with the molding impression; wherein the molding impression is configured so that a diameter of geometry spheres inscribed in said molding impression and having at least one point of contact with the sacrificial insert is no more than one and a half times (1.5 times) a critical diameter of the metallic alloy, optionally no more than one and two tenths times (1.2 times) the critical diameter of the metallic alloy, or no more than one time (1 time) the critical diameter of the metallic alloy. ### Claim 2 (depends on 1) The device according to claim 1, wherein said cavity is configured so that, after removing a part provided with the sacrificial insert from the mold, at least said contact zone of the rear face of the sacrificial insert is uncovered. ### Claim 3 (depends on 1) The device according to claim 1, wherein the cavity has a peripheral face joined to the receiving face. ### Claim 4 (depends on 1) The device according to claim 1, wherein a peripheral edge of the receiving face is joined to an end edge, which is adjacent thereto, of the peripheral face of the cavity. ### Claim 5 (depends on 1) The device according to claim 1, wherein the sacrificial insert is in the form of a plate. ### Claim 6 (depends on 1) The device according to claim 1, wherein said frontal molding face comprises a face of the cavity of the mold. ### Claim 7 (depends on 1) The device according to claim 1, wherein the frontal molding face comprises a frontal face of the injection piston. ### Claim 8 (depends on 1) The device according to claim 1, wherein the contact zone of the rear face of the sacrificial insert is adhesively bonded on top of the contact zone of the receiving face of the mold cavity. ### Claim 9 (depends on 1) The device according to claim 1, wherein at least one portion of a periphery of the sacrificial insert is inserted between two portions of the mold. ### Claim 10 (depends on 1) The device according to claim 1, wherein the receiving face of the cavity has a recess wherein the sacrificial insert is at least partly engaged. ### Claim 11 (depends on 1) The device according claim 1, wherein the sacrificial insert comprises a plurality of superimposed layers defining between said layers, at least one extension space of an impression. ### Claim 12 (depends on 1) The device according to claim 1, wherein the sacrificial insert comprises at least one material having a thermal conductivity of at least 20 W m−1 K−1, optionally at least 40 W m−1 K−1. ### Claim 13 (depends on 1) The device according to claim 1, for manufacturing one or more parts having an elastic deformation capacity of at least 1.2%, optionally at least 1.5%. ### Claim 14 (depends on 1) A method for manufacturing at least one part comprising an amorphous metallic alloy, using an injection mold according to claim 1, comprising: placing said sacrificial insert on top of said receiving face of at least one portion of the mold, assembling portions of the mold, injecting into said molding impression a metal or a metallic alloy in a liquid state and solidifying the molded metal or metallic alloy to obtain a molded part having at least partially an amorphous structure, optionally having an amorphous structure, disassembling the mold portions and extracting a molded part provided with the sacrificial insert, and separating the sacrificial insert and the molded part. ### Claim 15 (depends on 1) A method for manufacturing at least one part made of an amorphous metallic alloy, using an injection mold according to claim 1, comprising: assembling portions of the mold, placing said sacrificial insert on top of said receiving face of at least one portion of the mold, injecting into said molding impression a metal or a metallic alloy in the liquid state and solidifying the molded metal or metallic alloy to obtain a molded part having at least partially an amorphous structure, optionally having an amorphous structure, disassembling the mold portions and extracting a molded part provided with the sacrificial insert, and separating the sacrificial insert and the molded part. ### Claim 16 (depends on 14) The method according to claim 14, wherein the mold comprising the sacrificial insert is heated prior to the injection to a temperature of between 250° C. and Tg+100° C., optionally between Tg−150° C. and Tg+30° C. and optionally to Tg±20° C., with Tg the glass transition temperature of the metallic alloy. ### Claim 17 (depends on 14) The method according to claim 14, wherein the insert and the molded part are separated by destroying the sacrificial insert, optionally by destroying the sacrificial insert by a selective chemical attack in a bath. ### Claim 18 (depends on 14) The method according to claim 14, comprising, before or after the separation, removing surplus material so as to obtain a definitive part. ### Claim 19 (depends on 14) The method according to claim 14, comprising a subsequent heat treatment of the molded part and/or of a definitive part obtained. ### Claim 20 (depends on 14) The method according to claim 14, wherein injecting the metallic alloy has a duration of less than 100 ms, optionally less than 50 ms and optionally still than 20 ms. ### Claim 21 (depends on 14) A part comprising amorphous metallic alloy able to be obtained according to the method according to claim 14, such that: the amorphous metallic alloy has: i) a ΔTx of less than 100° C., optionally less than 80° C. and optionally less than 60° C., ΔTx being the difference between the crystallization temperature Tx and the glass transition temperature Tg; and/or ii) a standardized thermal stability criterion ΔTx/(Tl−Tg) of less than 0.18, optionally less than 0.15 and optionally still less than 0.12, or less than 0.10; the part has a) a thickness of less than 100 μm and a height/thickness ratio greater than 8, or b) a thickness of less than 50 μm and a height/thickness ratio greater than 4, or c) a thickness of less than 40 μm and a height/thickness ratio greater than 2. ### Claim 22 (depends on 21) The part according to claim 21, wherein faces of flanks of the part formed by a sacrificial insert have a mean roughness Ra of less than 1 μm, optionally less than 0.5 μm and optionally less than 0.1 μm. ### Claim 23 (depends on 21) The part according to claim 21, wherein a metallic alloy has a Tl greater than 700° C.