Description: Liquidmetal Technologies (LMT) and the University of Southern California (USC)'s M.C. Gill Composites Center team up to develop manufacturing processes for large-scale bulk metallic glass (BMG) and fiber laminate systems for aerospace applications. The proposed innovation consists of the development of a process to manufacture thin BMG sheets (150mm x 300mm x 0.1-1mm) by tube casting and hot rolling along with a process to fabricate fiber metal laminates (FMLs) utilizing the BMG sheets thereof and carbon fiber prepregs. While Phase I would focus on development of a small-scale prototype, the completed Phase I work would also give insight into the feasibility of large-scale manufacturing processes, such as vertical continuous casting, flash processing, autoclave moulding, out-of-autoclave moulding, and press moulding, many of which would be explored in a potential Phase II effort. Thus, in Phase I the technology readiness level (TRL) of the proposed innovation would increase from 2 to 3, and in Phase II the TRL would increase from 3 to 5.

Benefits: The primary NASA application for the proposed innovation would be for protection from micro-meteroid and orbital debris (MMOD). The high strength-to-weight ratio and high impact resistance of the bulk metallic glass-fiber metal laminate composite would provide hypervelocity impact protection of space vehicles and satellites in the form of an outer wall bumper shield.

The development of methods to manufacture thin BMG sheets on a large scale as well as methods to fabricate FMLs in complex geometries and at large scales would not only greatly enhance aerospace vehicle protection but also appeal to a wide range of applications, such as consumer electronics, armor, aircrafts, and automobiles.