Replication of surface features from a master model to an amorphous metallic article

DETAILED DESCRIPTION The present invention provides a method for replicating surfaces and replicas prepared by this approach, and in particular for replicating fine-scale features of a size of one micrometer or smaller.
The replicas are made of a metallic material that is strong, durable, and exhibits the physical properties of metals, such as response to incident electromagnetic radiation and resistance to heat.
The replicas are highly accurate reproductions of the surfaces and surface features being replicated.
The approach is readily practiced on an industrial scale, permitting the large-scale production of replicas.
In accordance with the invention, a method of replicating the surface features of an article comprises the steps of preparing a master model having a preselected surface feature thereon which is to be replicated, and replicating the preselected surface feature of the master model.
The replication is accomplished by providing a piece of a bulk-solidifying amorphous metallic alloy having a thickness greater than a minimum depth of the surface feature, contacting the piece of the bulk-solidifying amorphous metallic alloy to the surface of the master model at an elevated replication temperature under an external replication pressing pressure, to transfer a negative copy of the preselected surface feature of the master model to the piece, and separating the piece having the negative copy of the preselected surface feature from the master model.
To achieve replication of fine-scale features on the order of 1 micrometer in size, the external replication pressing pressure is greater than about 260 pounds per square inch (psi).
Preferably, the elevated replicating temperature is from about 0.
75 T.
sub.
g to about 1.
2 T.
sub.
g, where T.
sub.
g is measured in .
degree.
C.
, most preferably from about 0.
75 T.
sub.
g to about 0.
95 T.
sub.
g.
The replication pressure is preferably from about 260 to about 40,000 psi, more preferably from about 2600 to about 40,000 psi.
The replica is made of a bulk-solidifying amorphous alloy