Metallic glasses from “alchemy” to pure science: Present and future of design,processing and applications of glassy metals

Metallic glasses, first discovered a half century ago, are currently among the most studied metallic materials. Available in sizes up to several centimeters, with many novel, applicable properties, metallic glasses have also been the focus of research advancing the understanding of liquids and of glasses in general.Metallic glasses (MGs), called also bulk metallic glasses (BMGs) (or glassy metals, amorphous metals, liquid metals) are considered to be the materials of the future. Due to their high strength, metallic glasses have a number of interesting applications, for example as coatings. Metallic glasses can also be corrosion resistant. Metallic glasses, and the crystalline materials derived from them, can have very good resistance to sliding and abrasive wear. Combined with their strength – and now, toughness – this makes them ideal candidates for bio-implants or military applications. Prestigious Journals such as “Nature Materials”, “Nature” frequently publish new findings on these unusual glass materials. Moreover Chinese and Asian scientists have also been showing an interest in the study of metallic glasses.This review paper is far from exhaustive, but tries to cover the areas of interest as it follows: a short history, the local structure of BMGs and the glass forming ability (GFA), BMGs’ properties, the manufacturing and some applications of BMGs and finally, about the future of BMGs as valuable materials.     

Additive Manufacturing of Precision Biomaterials

Biomaterials play a critical role in modern medicine as surgical guides, implants for tissue repair, and as drug delivery systems. The emerging paradigm of precision medicine exploits individual patient information to tailor clinical therapy. While the main focus of precision medicine to date is the design of improved pharmaceutical treatments based on “-omics” data, the concept extends to all forms of customized medical care. This includes the design of precision biomaterials that are tailored to meet specific patient needs. Additive manufacturing (AM) enables free-form manufacturing and mass customization, and is a critical enabling technology for the clinical implementation of precision biomaterials. Materials scientists and engineers can contribute to the realization of precision biomaterials by developing new AM technologies, synthesizing advanced (bio)materials for AM, and improving medical-image-based digital design. As the field matures, AM is poised to provide patient-specific tissue and organ substitutes, reproducible microtissues for drug screening and disease modeling, personalized drug delivery systems, as well as customized medical devices.     

Additive Design and Manufacturing of Jet Engine Parts

The additive design (AD) and additive manufacturing (AM) of jet engine parts will revolutionize the traditional aerospace industry. The unique characteristics of AM, such as gradient materials and micro-structures, have opened up a new direction in jet engine design and manufacturing. Engineers have been liberated from many constraints associated with traditional methodologies and technologies. One of the most significant features of the AM process is that it can ensure the consistency of parts because it starts from point(s), continues to line(s) and layer(s), and ends with the competed part. Collaboration between design and manufacturing is the key to success in fields including aerodynamics, thermodynamics, structural integration, heat transfer, material development, and machining. Engineers must change the way they design a part, as they shift from the traditional method of “subtracting material” to the new method of “adding material” in order to manufacture a part. AD is not the same as designing for AM. A new method and new tools are required to assist with this new way of designing and manufacturing. This paper discusses in detail what is required in AD and AM, and how current problems can be solved.     

“Smart” Surface Capsules for Delivery Devices

This review describes emerging trends, basic principles, applications, and future challenges for designing next generation responsive “smart” surface capsules. Advances and importance of “surface” capsules which are not deposited onto the surface but are built into the surface are highlighted for selective applications with specific examples of surface sponge structures formed by high intensity ultrasonic surface treatment (HIUS). Surface capsules can be adapted for biomedical applications, membrane materials, lab‐on‐chip, organ‐on‐chip, and for template synthesis. They provide attractive self‐healing anticorrosion and antifouling prospects. Nowadays delivery systems are built from inorganic, organic, hybrid, biological materials to deliver various drugs from low molecular weight substances to large protein molecules and even live cells. It is important that capsules are designed to have time prolonged release features. Available stimuli to control capsule opening are physical, chemical and biological ones. Understanding the underlying mechanisms of capsule opening by different stimuli is essential for developing new methods of encapsulation, release, and targeting. Development of “smart” surface capsules is preferable to respond to multiple stimuli. More and more often a new generation of “smart” capsules is designed by a bio‐inspired approach.     

Microstructure,static properties,and fatigue crack growth mechanisms in Ti-6Al-4V fabricated by additive manufacturing: LENS and EBM

Additive manufacturing (AM) technology is capable of building 3D near-net-shaped functional parts directly from computer models using unit materials, such as powder or wire. Additive manufacturing's computer-aided design offers superior geometrical flexibility. The near-net-shaping capability also significantly reduces materials waste. These benefits make AM desirable for critical applications, such as aerospace, ground transportation, and medical. Confident utilization of the technology requires thorough understanding of the AM materials, ensuring that structural integrity and performance requirements are met or exceeded. In this study, Ti-6Al-4V fabricated by two AM techniques: Laser Engineered Net Shaping (LENS) and Electron Beam Melting (EBM) were investigated and critically compared. Samples were built using various processing parameters and heat treated under different conditions, which resulted in different microstructures and mechanical properties. Characteristic microstructures were determined for all cases. Room temperature tensile and fatigue crack growth properties were also evaluated and compared in different orientations with respect to the building direction. The effects of post-AM heat treatments on microstructure and properties were also studied. The results are systematically presented and discussed from the material/process optimization, structural design, and fatigue life prediction perspectives.     

Decoding the glass genome

Glasses have played a critical role in the development of modern civilization and will continue to bring new solutions to global challenges from energy and the environment to healthcare and information/communication technology. To meet the accelerated pace of modern technology delivery, a more sophisticated approach to the design of advanced glass chemistries must be developed to enable faster, cheaper, and better research and development of new glass compositions for future applications. In the spirit of the U.S. Materials Genome Initiative, here we describe an approach for designing new glasses based on a mathematical optimization of composition-dependent glass property models. The models combine known physical insights regarding glass composition-property relationships together with data-driven approaches including machine learning techniques. Using such a combination of physical and empirical modeling approaches, we seek to decode the “glass genome,” enabling the improved and accelerated design of new glassy materials.     

Werkstoffkundliche Basis für die Konstruktion mit Ingenieurkeramik

Fundamental Properties for the Design with Engineering Ceramics Within the class of technical ceramics a new group of high quality materials has been developed, called “engineering ceramics”. A definition is given, some of their properties and future applications for mechanical design are pointed out. Comparing to the fundamental properties and definitions known for metallic materials the distinctions and different approach for the design with engineering ceramics are discussed.     

Latest Developments in Modeling and Characterization of Joining Metal Based Hybrid Materials

Advanced materials consist of several materials systems that exhibit complementary properties for multi‐purpose applications. Joining of dissimilar materials is a critical and challenging advanced manufacturing technique to develop novel hybrid materials with properties fully transferred. The “bonding strength” of a joint is crucial for its integrity and performance. The bonding strength is affected by a range of parameters that can be better understood, controlled, and optimized via both experimental and analytical approaches. In this paper, the authors review the theoretical and experimental studies of the interface inside several metal based composites. The scope includes interface bonding's critical parameters, characterization techniques of joining processes, potential applications, and their future perspectives. The review is significant to develop advanced manufacturing techniques for heterogeneous materials and to design innovative heterogeneous systems for various medical, electrical, electronics, industrial, and other daily life applications that involve the broad range of “joining” processes.

     

Powder-Based Additive Manufacturing: A Critical Review of Materials,Methods, Opportunities,and Challenges

As a 0D material, powder particles can be used to create almost any complicated engineering component by utilizing the high-performance manufacturing capabilities of additive manufacturing (AM). Although powder-based AM methods provide an outstanding practical value and development for modern manufacturing world, they continue to face challenges such as a lack of accessible categories, temperature restrictions, and poor performance of molded components. Therefore, researching for new AM materials and procedures has become an extremely necessary endeavor. For this purpose, a firm grasp of the current state of the art of powder-based AM technologies is imperative. Hence, herein, a comprehensive review is presented on the most widely used powder-based AM methods, and the materials used by these methods. For each method, the development and current state, operating principles, limitations, and future prospects are summarized. In contrast, for materials, their classifications, properties, and preparation methods are explored in great detail, while also commenting on the specific compatibilities between powder materials and powder methods. Industrial and commercialized applications of powder-based AM are also presented in this work. Finally, the limitations of the current powder-based technologies are highlighted, with comments regarding the future of this field.     

Alloy design via additive manufacturing: Advantages,challenges, applications and perspectives

Additive manufacturing (AM) has rapidly changed both large- and small-scale production environments across many industries. By re-envisioning parts from the ground up, not limited to the challenges presented by traditional manufacturing techniques, researchers and engineers have developed new design strategies to solve large-scale materials and design problems worldwide. This is particularly true in the world of alloy design, where new metallic materials have historically been developed through tedious processes and procedures based primarily on casting methodologies. With the onset of directed energy deposition (DED) and powder bed fusion (PBF)-based AM, new alloys can be innovated and evaluated rapidly at a lower cost and considerably shorter lead time than has ever been achieved. This article details the advantages, challenges, applications, and perspectives of alloy design using primarily laser-based AM. It is envisioned that researchers in industry and academia can utilize this work to design new alloys leveraging metallic AM processes for various current and future applications.     

Functional Materials and Systems for Rewritable Paper

“Paper” has greatly contributed to the development and spread of civilization. Even in today's “digitalized” world, paper continues to play a key role in socioeconomic growth, as is evidenced by the growth in global paper consumption. Unfortunately, the use of paper has its cost in terms of the exhaustion of world's natural resources. Consequently, new, cost‐effective technologies that preserve natural resources are required for this purpose. Functional materials have revolutionized the way people think about developing new technologies. Especially important in this regard are “smart reactive materials,” which are capable of actively responding to external stimuli such as heat, light, mechanical stress, and specific molecular orientations. Moreover, functionalized chromogenic materials, which undergo reversible color switching upon external stimulation, have attracted great attention in the context of developing rewritable paper. Here, investigations of various materials and systems that are devised for use as rewritable paper are reviewed with the hope that the coverage will stimulate and guide future studies in this area.     

Ti3C2TX MXene Ink Direct Writing Flexible Sensors for Disposable Paper Toys

Flexible electronics have gained great attention in recent years owing to their promising applications in biomedicine, sustainable energy, human-machine interaction, and toys for children. Paper mainly produced from cellulose fibers is attractive substrate for flexible electronics because it is biodegradable, foldable, tailorable, and light-weight. Inspired by daily handwriting, the rapid prototyping of sensing devices with arbitrary patterns can be achieved by directly drawing conductive inks on flat or curved paper surfaces; this provides huge freedom for children to design and integrate “do-it-yourself (DIY)” electronic toys. Herein, viscous and additive-free ink made from Ti₃C₂T_X MXene sediment is employed to prepare disposable paper electronics through a simple ball pen drawing. The as-drawn paper sensors possess hierarchical microstructures with interweaving nanosheets, nanoflakes, and nanoparticles, therefore exhibiting superior mechanosensing performances to those based on single/fewer-layer MXene nanosheets. As proof-of-concept applications, several popular children's games are implemented by the MXene-based paper sensors, including “You say, I guess,” “Emotional expression,” “Rock-Paper-Scissors,” “Arm wrestling,” “Throwing game,” “Carrot squat,” and “Grab the cup,” as well as a DIY smart whisker for a cartoon mouse. Moreover, MXene-based paper sensors are safe and disposable, free from producing any e-waste and hazard to the environment.     

Graphene‐Based Smart Platforms for Combined Cancer Therapy

The extensive research of graphene and its derivatives in biomedical applications during the past few years has witnessed its significance in the field of nanomedicine. Starting from simple drug delivery systems, the application of graphene and its derivatives has been extended to a versatile platform of multiple therapeutic modalities, including photothermal therapy, photodynamic therapy, magnetic hyperthermia therapy, and sonodynamic therapy. In addition to monotherapy, graphene‐based materials are widely applied in combined therapies for enhanced anticancer activity and reduced side effects. In particular, graphene‐based materials are often designed and fabricated as “smart” platforms for stimuli‐responsive nanocarriers, whose therapeutic effects can be activated by the tumor microenvironment, such as acidic pH and elevated glutathione (termed as “endogenous stimuli”), or light, magnetic, or ultrasonic stimuli (termed as “exogenous stimuli”). Herein, the recent advances of smart graphene platforms for combined therapy applications are presented, starting with the principle for the design of graphene‐based smart platforms in combined therapy applications. Next, recent advances of combined therapies contributed by graphene‐based materials, including chemotherapy‐based, photothermal‐therapy‐based, and ultrasound‐therapy‐based synergistic therapy, are outlined. In addition, current challenges and future prospects regarding this promising field are discussed.     

Additive manufacturing of high entropy alloys:A practical review

The novel idea of alloying,which is based on the utilization of multiple principal elements in high concen-trations,has created a novel class of promising materials called high entropy alloys(HEAs).So far,several HEAs with outstanding properties beyond those of conventional alloys have been discovered,and new superior high-entropy alloys are still expected to be developed in the future.However,the fabrication process of HEAs through conventional manufacturing techniques suffers from significant limitations due to the intrinsic requirements of HEAs.Additive manufacturing(AM),on the other hand,has provided new opportunities for fabricating geometrically complex HEAs with the possibility of in situ tailoring of their microstructure features.Considering the growing interest in AM of HEAs during most recent years,this review article aims at providing the state of the art in AM of HEAs.It describes the feedstock requirements for laser based AM techniques.Thereafter,a comprehensive picture of the current state of nearly all HEAs processed by laser metal deposition(LMD),selective laser melting(SLM)and selec-tive electron beam melting(SEBM)is presented.Special attention is paid to the features of AM derived microstructures along with their outstanding properties and underlying mechanisms for various mate-rial processing combinations.The AM of interstitial solute hardening HEAs,HEA matrix composites as well as non-beam based AM of HEAs will also be addressed.The post-AM treatments and the strategies to fabricate defect-free HEAs are summarized.Finally,a conclusion of current state and future prospects of additive manufacturing of HEAs will be presented.     

Stimulus Responsive 3D Assembly for Spatially Resolved Bifunctional Sensors

3D electronic/optoelectronic devices have shown great potentials for various applications due to their unique properties inherited not only from functional materials, but also from 3D architectures. Although a variety of fabrication methods including mechanically guided assembly have been reported, the resulting 3D devices show no stimuli‐responsive functions or are not free standing, thereby limiting their applications. Herein, the stimulus responsive assembly of complex 3D structures driven by temperature‐responsive hydrogels is demonstrated for applications in 3D multifunctional sensors. The assembly driving force, compressive buckling, arises from the volume shrinkage of the responsive hydrogel substrates when they are heated above the lower critical solution temperature. Driven by the compressive buckling force, the 2D‐formed membrane materials, which are pre‐defined and selectively bonded to the substrates, are then assembled to 3D structures. They include “tent,” “tower,” “two‐floor pavilion,” “dome,” “basket,” and “nested‐cages” with delicate geometries. Moreover, the demonstrated 3D bifunctional sensors based on laser induced graphene show capability of spatially resolved tactile sensing and temperature sensing. These multifunctional 3D sensors would open new applications in soft robotics, bioelectronics, micro‐electromechanical systems, and others.     

Recent development in 2D materials beyond graphene

Discovery of graphene and its astonishing properties have given birth to a new class of materials known as “2D materials”. Motivated by the success of graphene, alternative layered and non-layered 2D materials have become the focus of intense research due to their unique physical and chemical properties. Origin of these properties ascribed to the dimensionality effect and modulation in their band structure. This review highlights the recent progress of the state-of-the-art research on synthesis, characterization and isolation of single and few layer nanosheets and their assembly. Electronic, magnetic, optical and mechanical properties of 2D materials have also been reviewed for their emerging applications in the area of catalysis, electronic, optoelectronic and spintronic devices; sensors, high performance electrodes and nanocomposites. Finally this review concludes with a future prospective to guide this fast evolving class of 2D materials in next generation materials science.     

Conjugated Polymer Actuators and Devices: Progress and Opportunities

Conjugated polymers (CPs), as exemplified by polypyrrole, are intrinsically conducting polymers with potential for development as soft actuators or “artificial muscles” for numerous applications. Significant progress has been made in the understanding of these materials and the actuation mechanisms, aided by the development of physical and electrochemical models. Current research is focused on developing applications utilizing the advantages that CP actuators have (e.g., low driving potential and easy to miniaturize) over other actuating materials and on developing ways of overcoming their inherent limitations. CP actuators are available as films, filaments/yarns, and textiles, operating in liquids as well as in air, ready for use by engineers. Here, the milestones made in understanding these unique materials and their development as actuators are highlighted. The primary focus is on the recent progress, developments, applications, and future opportunities for improvement and exploitation of these materials, which possess a wealth of multifunctional properties.     

Metal Alloys for Fusion‐Based Additive Manufacturing

Metal additive manufacturing (AM) is an innovative manufacturing technique, which builds parts incrementally layer by layer. Thus, metal AM has inherent advantages in part complexity, time, and waste saving. However, due to its complex thermal cycle and rapid solidification during processing, the alloys well suit and commercially used for metal AM today are limited. Therefore, it is important to understand the alloying strategy and current progress with materials performance to consider alloy development for metal AM. This review presents the current range of alloys available for metal AM, including titanium, steel, nickel, aluminum, less common alloys (including Mg alloys, metal matrix composites alloys, and low melting point alloys), and compositionally complex alloys (including bulk metallic glasses and high entropy alloys) with a focus on the relationship between compositions, processing, microstructures, and properties of each alloy system. In addition, some promising alloy systems for metal AM are highlighted. Approaches for designing and optimizing new materials for metal AM have been summarized.

     

Tailoring the Mechanical Properties of 3D Microstructures Using Visible Light Post‐Manufacturing

The photochemistry of anthracene, a new class of photoresist for direct laser writing, is used to enable visible‐light‐gated control over the mechanical properties of 3D microstructures post‐manufacturing. The mechanical and viscoelastic properties (hardness, complex elastic modulus, and loss factor) of the microstructures are measured over the course of irradiation via dynamic mechanical analysis on the nanoscale. Irradiation of the microstructures leads to a strong hardening and stiffening effect due to the generation of additional crosslinks through the photodimerization of the anthracene functionalities. A relationship between the loss of fluorescence—a consequence of the photodimerization—and changes in the mechanical properties is established. The fluorescence thus serves as a proxy read‐out for the mechanical properties. These photoresponsive microstructures can potentially be used as “mechanical blank slates”: their mechanical properties can be readily adjusted using visible light to serve the demands of different applications and read out using their fluorescence.     

Zero Linear Compressibility in Nondense Borates with a “Lu‐Ban Stool”‐Like Structure

Discovering materials that exhibit zero linear compressibility (ZLC) behavior under hydrostatic pressure is extremely difficult. To date, only a handful of ZLC materials have been found, and almost all of them are ultrahard materials with densified structures. Here, to explore ZLC in nondense materials, a structural model analogous to the structure of the “Lu‐Ban stool,” a product of traditional Chinese woodworking invented 2500 years ago, is proposed. The application of this model to borates leads to the discovery of ZLC in AEB₂O₄ (AE = Ca and Sr) with the unique “Lu‐Ban stool”‐like structure, which can obtain a subtle mechanical balance between pressure‐induced expansion and contraction effects. Coupled with the very wide ultraviolet transparent windows, the ZLC behavior of AEB₂O₄ may result in some unique but important applications. The applications of the “Lu‐Ban stool” model open a new route for pursuing ZLC materials in nondense structural systems.