Development of bulk metallic glass components for spacecraft applications using thermoplastic forming

Ever increasing demands on space, aerospace and defense applications require non-traditional approaches to materials and processing methods. Bulk metallic glasses (BMGs) are unique materials that combine properties of ultrahigh strength metals with processability of thermoplastics, which is often paired with other attractive attributes, such as high elasticity, fracture toughness, fatigue limit, hardness, corrosion and wear resistance. This project is focused on thermoplastic forming (TPF) of BMGs. This technology enables a wide range of geometries and functionalities that are not possible with other materials and processing methods. Furthermore, compared to other BMG processing methods such as casting, TPF results in consistently high properties in fabricated BMG parts. The goal for Phase II is to advance commercial opportunities for TPF of BMGs for structural and functional spacecraft applications, specifically focusing on flexures and propellant tanks. The scope of work includes fabrication of prototypes of different types BMG flexures and conducting full testing of flexures and associated actuator devices that are used in satellites. For propellant tanks, we will conduct necessary testing of BMG alloys and fabricate a proof-of-concept shape. Both actuators and propellant tanks have a wide applicability in Air Force, Defense and commercial applications and are expected to bring significant benefits.