Effect of Melt State on Glass Formation and Mechanical Behavior of a CuZrAl Ternary Bulk Metallic Glass

Bulk metallic glasses (BMGs), classified as metastable materials, necessitate melt quenching at critical cooling rates higher than 102 K/s to kinetically bypass crystalline phase formation during solidification. Owing to this rapid quenching, the microstructure of BMGs can be regarded as melt quenched. This study examines how their melt state governs the thermal stability, structural characteristics, and plasticity behavior of Zr50Cu40Al10 BMG. Rod samples were prepared via injection casting at controlled melt temperatures and suction casting. Experimental observations demonstrated a positive correlation between elevated melt temperatures and enhanced glass forming ability (GFA) along with improved thermal stability (T-A) in BMGs during processing. Structural analyses confirmed the glassy nature of the prepared BMGs with different melt states and revealed their temperature-dependent atomic-scale heterogeneity: the samples quenched at low melt temperatures exhibited significant Cu-rich clustering as determined via energy-dispersive X-ray spectroscopy (EDS) mapping, and those at high melt temperatures formed homogeneous structures. This structure heterogeneity was directly correlated with good plastic deformation behavior, i.e., the rod sample prepared at the lowest melt temperature achieved 9.7% plastic strain. The transition is attributed to liquid-liquid phase transition (LLPT): below the LLPT threshold, metastable Cu-rich clusters persist in the melt and are retained upon quenching, creating structural defects that facilitate shear band multiplication. These findings highlight melt temperature as a crucial factor in tailoring the structure characteristic and mechanical behavior of Zr50Cu40Al10 BMGs.