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Laser Engineered Net Shaping (LENS™) is a laser-assisted manufacturing process that offers the possibility of producing metallic coatings and components with highly nonequilibrium microstructures. In this work, the microstructure developed by LENS deposition of Cu 47 Ti 33 Zr 11 Ni 8 Si 1 powder on a bulk metallic glass substrate, with nominal composition Zr 58.5 Nb 2.8 Cu 15.6 Ni 12.8 Al 10.3 , is investigated. Single-layer deposition results in the formation of an inhomogeneous but partially amorphous layer above a crystalline heat-affected zone. Elemental analysis of the deposited layer indicates incomplete mixing of the powder with the melt pool. The as-deposited alloy exhibits a single glass transition event and its primary crystallization event is consistent with the first crystallization temperature of the Cu-based powder. Subsequent remelting of this layer results in a still partially amorphous deposit with a uniform composition of (Zr + Nb) 51.8 Cu 24.7 Ti 3.4 Ni 16.4 Al 3.7 . The remelted layer exhibits a structural rearrangement immediately prior to the primary crystallization event, possibly associated with the formation of a quasicrystalline phase.

Laser processing is a precision manufacturing technique capable of producing materials with highly nonequilibrium microstructures. Due to the localized heat input and high cooling rate inherent to the process, this technology is attractive for the production of metallic glasses. In the present work, we use a laser deposition process to deposit a Zr-based metallic glass forming powder on both amorphous and crystalline substrates of the same nominal composition. Amorphous melt zones are observed surrounded by distinct crystalline heat-affected zones (HAZs). Detailed examination of the HAZ in the glassy substrates reveals the formation of microscale spherulites, in contrast to the nanocrystalline phases observed following crystallization by isothermal annealing of the glass at the crystallization temperature as well as in the HAZ of the crystalline substrates. The spherulites have a different crystal morphology and structure from the nanocrystalline phases, indicating that the more stable nanocrystalline phases are completely bypassed when the glass is devitrified at the higher heating rate. Reducing the heat input during laser processing results in the near elimination of the crystalline HAZ in the amorphous substrates, suggesting that a critical heating rate range is required to avoid devitrification.

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