Patent ID: 7361239

Claim:
A method of forming a metallic glass composite of 10 to 50 vol % metallic glass alloy and 50 to 90 vol % refractory metal, wherein the metallic glass alloy is Hf-based, the refractory metal is tungsten and the structural composite has a density range of about 16.0-18.5 g/cm 3 , and a desired shape and size comprising: heating a mixture of metallic glass alloy powder and refractory metal powder in a closed chamber for a period of time, wherein the metallic glass alloy powder comprises 10 to 50 vol % of the mixture and refractory metal powder comprises 50 to 90 vol % of the mixture, and wherein the temperature inside the chamber is a first temperature less than the glass transition temperature (T g ) of the metallic glass alloy powder, and wherein the period of time, the temperature, and the pressure inside the chamber selected promote consolidation; further heating and pressing said mixture to a second temperature for a second period of time, wherein the second temperature is greater than the single crystallization event temperature (T x ) of the metallic glass alloy powder and less than about 50° C. above the liquidus temperature of the metallic glass alloy powder, and wherein the pressing of said mixture forms a desired shape and size; and immediately cooling said mixture once the second temperature is reached to obtain a metallic glass composite, whereby the formation of a third phase along the metallic glass alloy/refractory metal interface is controlled.