Systems and methods for implementing robust gearbox housings
Systems and methods in accordance with embodiments of the invention efficaciously implement robust gearbox housings. In one embodiment, a method of fabricating a gearbox housing includes: providing an alloy composition from which the gearbox housing will be fabricated from; casting the alloy composition around a solid body so as to form a part characterized by the inclusion of a cavity, where the cast part includes a metallic glass-based material; and nondestructively separating the cast part from the solid body.
1. A method of manufacturing a gearbox housing comprising: selecting an alloy composition from which the gearbox housing will be fabricated, wherein the alloy composition is configured to form, when cast, a metallic glass-based material characterized by:
a Young's modulus of less than 110 GPa,
a fracture toughness of between 20 MPa m 1/2 and approximately 200 MPa m 1/2 ,
a Rockwell C hardness of greater than 45,
an elastic limit of greater than 1%, and
a solidification shrinkage of less than 1.5;
casting the alloy composition around a solid body so as to form a cast part formed of the metallic glass-based material and characterized by a cavity disposed therein and defined by an outer contour of the solid body;
wherein the cast part is further characterized by a plurality of gear teeth disposed about an inner lining of the cavity;
and
nondestructively separating the cast part from the solid body.
2. The method of claim 1 , further comprising implementing gear teeth onto the lining of the cavity.
3. The method of claim 2 , wherein the implementing of gear teeth is achieved via machining.
4. The method of claim 3 , wherein the machining is achieved via electron discharge machining.
5. The method of claim 1 , wherein the alloy composition is based on one of: Ti, Zr, Cu, Ni, Fe, Pd, Pt, Ag, Au, Al, Hf, W, Be, and combinations thereof.
6. The method of claim 5 , wherein the alloy composition is based on Titanium.
7. The method of claim 1 , wherein the metallic glass-based material is disposed throughout the cast part.
8. The method of claim 1 , wherein the solid body is cylindrical.
9. The method of claim 1 , wherein the solid body comprises a crystalline metal.
10. The method of claim 9 , wherein the solid body is entirely comprised of the crystalline metal.
11. The method of claim 9 , wherein the crystalline metal is brass.
12. The method of claim 1 , wherein the cast part is cup-shaped.
13. The method of claim 1 , wherein the cast part is characterized by a density of less than 5.5 g/cm 3 .