Patent ID: 7588071

Claim:
A method of manufacturing a continuous sheet of a metallic glass foam from a bulk-solidifying amorphous alloy comprising: providing a quantity of a bulk solidifying amorphous alloy foam precursor at a casting temperature around the melting temperature of the alloy; stabilizing the bulk solidifying amorphous alloy at a casting temperature below the melting temperature [T m ] of the alloy and above the temperature at which crystallization occurs on the shortest time scale for the alloy [T NOSE ] such that the viscosity of the bulk solidifying amorphous alloy is from about 0.1 to 10,000 poise; introducing the stabilized bulk solidifying amorphous alloy foam precursor onto a moving casting body such that a continuous sheet of heated bulk solidifying amorphous alloy is formed thereon; and quenching the heated bulk solidifying amorphous alloy foam precursor at a quenching rate sufficiently fast such that the bulk solidifying amorphous alloy remains in a substantially amorphous phase to form a solid amorphous continuous foam sheet having a thickness of at least 0.1 mm.