This paper details a systematic investigation of the formation of Al-based bulk metallic glasses, expanding on an earlier brief report [Scripta Mater. 61 (2009) p.423]. We discuss an approach for designing and predicting the best glass-forming composition in the Al-TM-RE systems, based on the atomic cluster packing model for the internal structure of the glass. The effects of additional elements in quaternary and quinary systems on the glass-forming ability and thermal stability of the glasses are also discussed. Three new compositions, Al86Ni6Y4.5Co2La1.5, Al86Ni7Y5Co1La1 and Al86Ni7Y4.5Co1La1.5, are capable of forming fully glassy rods of 1 mm in diameter; their glass transition and other thermal properties are systematically characterized.
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