SHEAR-ASSISTED EXTRUSION CONFIGURATIONS

BACKGROUND

This document pertains generally, but not by way of limitation, to solid-phase processing of materials for extrusion applications, and more particularly to techniques and related apparatus configurations for performing shear-assisted extrusion.

Metal extrusion is a metal-forming manufacturing process in which a cylindrical billet inside a closed cavity is forced to flow through a die aperture. The resulting extruded parts are called extrudates. The process was first used to extrude lead pipes. In addition to metals, plastics and ceramics can also be extruded.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings, which are not necessarily drawn to scale, like numerals may describe similar components in different views. Like numerals having different letter suffixes may represent different instances of similar components. The drawings illustrate generally, by way of example, but not by way of limitation, various embodiments discussed in the present document.

FIG. 1A illustrates, by way of example and not limitation, a portion of a system for extruding a structure having a hollow circular cross section.

FIG. 1B illustrates, by way of example and not limitation, a portion of a system for extruding a structure having a hollow circular cross section.

FIG. 2 illustrates, by way of example and not limitation, portions of a system for extruding a structure having a hollow cross section.

FIG. 3A illustrates, by way of example and not limitation, a top isometric view of a porthole die showing a scroll face and portholes.

FIG. 3B illustrates, by way of example and not limitation, a bottom isometric view of a porthole die showing portholes and a mandrel.

FIG. 4A illustrates, by way of example and not limitation, a cross-section view of a portion of a system including a die tool and a billet system for extruding a structure having a hollow cross section.

FIG. 4B illustrates, by way of example and not limitation, a cross-section view of a portion of a system including a die tool and a billet system for extruding a structure having a hollow cross section.

FIG. 5 illustrates, by way of example and not limitation, a section view of a portion of a system including a die tool and a billet system for extruding a structure having a hollow cross section.

FIG. 6 illustrates, by way of example and not limitation, a section view of a portion of a system including a die tool and a billet system for extruding a structure having a hollow cross section.

FIG. 7A illustrates, by way of example and not limitation, a section view of a portion of a system including a die tool and a billet system for extruding a structure having a hollow cross section.

FIG. 7B illustrates, by way of example and not limitation, a section view of a portion of a system including a die tool and a billet system for extruding a structure having a hollow cross section.

FIG. 8 illustrates, by way of example and not limitation, an example of a flowchart of a method for extruding hollow cross-section pieces.

DETAILED DESCRIPTION

Shear assisted extrusion processes (ShAPE) are discussed herein, including a variety of approaches for rotational and axial movement. Such rotational and axial movement can be used to establish a rotational shearing force or an axial extrusion force to form an extrudate. For example, the extrudate may not rotate as the extrusion feedstock material is being extruded using rotational and axial movement imparted on the extrusion feedstock material. A billet of a billet feedstock material to be extruded can be placed in a container. A portion of the billet material within the container can be extruded through an extrusion aperture in response to a rotational shearing force and an axial extrusion force established at a face of a portion of billet material engaged by a die tool. The billet, the die, the container, or a ram may be rotated. Likewise, the billet, the die, the container or the ram may be moved axially. In response to the die not being rotated, the extrudate can be extruded without being rotated.

The present techniques of shear-assisted extrusion can be used to form a solid or hollow-profile extrudate of a desired composition from one or more feedstock billets. A rotational shearing force (or a rotational shear or a rotation-induced shear force) and an axial extrusion force can be concurrently applied to the same location on the billet material, such as using the extrusion die face or a container holding the billet material. Plasticized billet material can be directed through the extrusion aperture. After traversing the extrusion aperture, the plasticized material has been configured into a desired shape and, in the instance where the extruded structure is not rotated, the desired shape may be maintained. In contrast, if the extruded structure is allowed to rotate, the extruded structure may begin to warp or become disfigured after exiting the die during the extrusion process.

The present techniques can help provide a number of potential advantages. For example, the resulting extrudate can be tubular with a particular shape that is maintained throughout the extrusion process. The present extrusion techniques can also help form an extrudate that can have better strength, electrical conductivity, corrosion resistance, or less porosity, such as compared to approaches that do not use a combination of rotational and axial forces to shear-assist the extrusion process. Such characteristics can be obtained at lower temperatures, lower forces, or with lower extrusion force and electrical power as compared to non-shear-assisted processing. The present techniques can be useful in a variety of industries and applications including but not limited to one or more of transportation, projectiles, high temperature applications, structural applications, nuclear applications, or corrosion resistance applications. Metallurgy of alloy or composite materials desired for extrusion or other processing can present various challenges.

In the field of energy conversion and energy transport, there is a need to develop materials (e.g., alloys, composites, etc.) with improved electrical performance, specifically higher electrical conductivity and current density. In electrical applications, such as in overhead conductors, motors, inverters, and generators, copper and aluminum, and various alloys thereof, are desirable materials. These alloys (such as C10100, C11000, C15000, AA1100, AA1350, AA8002) may seek to have minimal impurities, but occasionally can benefit from additives that can help improve one or more of mechanical performance, wear resistance, or corrosion resistance of the metal substrates, but certain approaches may involve sacrificing electrical conductivity. Introducing additives in a metal may increase charge scattering, which, in turn, can lead to detrimental electrical carrier transport properties. There is a need for technology in which one or more additives can be introduced into a metal such as to make an alloy or composite for improving electrical performance.

The present techniques can help address one or more of the challenges mentioned above, such as producing feedstock for other processing or producing finished components. For example, the present techniques can help enable extrusion of metal wires, bars, or tubes. Hollow structures can have an easily specifiable—or even variable—thickness within the same extruded product. This extrusion process can yield extrusion products from lightweight materials, such as magnesium and aluminum alloys, with improved mechanical properties. The extrusion process can go directly to extrudate from powder, flake, or billet feedstocks in as few steps as a single step. This can help reduce the overall energy consumption and processing time for extrusion.

Combining linear compression and rotational shearing can result in lower extrusion force compared to certain other extrusion approaches. As an illustration, a size of any hydraulic ram, supporting components, mechanical structure, and overall footprint can be scaled down. This can help in enabling smaller production machinery. Plasticizing energy for extrusion can be provided via friction at the interface between the billet and a scroll-faced or other extrusion die. Such plastic shear deformation within the extruding material need not require the preheating and external heating of the billet material used by other methods, or such preheating can be significantly less energy intensive as compared to non-shear-assisted approaches. This can reduce power consumption. Extrusion ratios up to 200:1 can be achieved for many alloys using the present techniques.

Devices for performing shear assisted extrusion using a variety of rotational or axial movement are also described. For example, an extrusion device can include a die tool. The die tool can include a die face. The die tool can define a die orifice that can extend at least partially through the die (e.g., including the die face). A central longitudinal axis can be defined as extending through the die face orifice, such as at a center of the die face orifice. The die tool, the billet, the container, and/or a ram can be configured to rotate about the central longitudinal axis and/or move axially along the central longitudinal axis to engage with other elements of the extrusion system. For example, the billet can rotate about and move axially along the central longitudinal axis and thereby engage with the die tool (where the die tool is not rotating or moving axially). Further, the die tool may move axially and the billet rotate about the central longitudinally axis, thereby causing the die face of the die tool to engage with the billet. Further variations will be described herein.

Shear assisted extrusion processes (ShAPE) are provided, such as for forming an extrudate using a variety of rotational or axial movements. The shear assisted extrusion processes can include providing axial and shear forces established at an interface between a die and a feedstock, where heat will be generated, and such heating can plasticize the materials in or around the die face and opening. The heating generated by the extrusion process itself, and resulting plasticization, can enable generation of extrudate with solid or hollow core cross-sections.

The above discussion is intended to provide an overview of subject matter of the present patent application. It is not intended to provide an exclusive or exhaustive explanation of the invention. The description below is included to provide further information about the present patent application.

FIGS. 1A and 1B illustrate, by way of example and not limitation, a system 100 for extruding a structure having a hollow cross section using a shear-assisted direct extrusion technique. FIGS. 1A and 1B are discussed together below. This can include using shear-assisted processing involving applying an axial compression force and a rotation-induced shear force. As shown in FIG. 1A, a die assembly 110 can include a die face 128 that can be thrust against and into a billet material 120 (or vice versa). The die face 128 can include one or more scrolls (e.g., a fluted or spiral topology defining surface contours that direct plasticized material inward as the die face 128 rotates relative to the billet material 120, illustrated further in FIG. 3A), the die face 128 can include other surface features, or it can even be flat. The billet material 120 can be held within a billet holder assembly 112 (or container assembly) that can include a container base 112A and a container sidewall 112B. The scrolls can include various fluted, spiral, or other patterns or styles of topology including constant curvature pitch and non-constant curvature pitch.

A die shank 114 of the die assembly 110 can be retained within a die holder 121 of the die assembly 110 and with the die face 128 operably engaged with the billet material 120 to create a high shear region 126 at the die face 128. The rotation (illustrated by the rotating arrow R, about a rotational axis 135) and the axial movement (illustrated by the double-sided arrow T) of the die assembly 110 including the die face 128 can induce shear to plasticize the billet material 120 at or adjacent to the interface (126) between the die face 128 and the billet material 120. The plasticized material can flow in a specified direction.

As shown in FIG. 1B, the system 100 can also be configured such that the billet holder assembly 112 and billet material 120 spin and the die face 128 can be translated axially into the billet material 120 such as to provide a combination of shear and compressive forces at the interface between the billet material 120 and the die face 128. Regardless of which structure is rotated or translated (rammed) in absolutely space relative to the other, the net effect is relative rotation and axial force between the die face 128 and the billet 120 which in turn cause an extrude 118 to flow out from the die orifice 138 of the die assembly 110.

Flow of the plasticized material can then be directed, such as through an extrusion aperture, to another location, such as an internal portion 111 of the die assembly 110. The die face 128 can define a die face orifice 138. A longitudinal axis (or “central longitudinal axis”) 135 can be defined to extend through a center of the die face orifice 38. The billet holder assembly 112 and the billet material 120 can rotate about the central longitudinal axis 135 to permit the die face 128 to engage the billet material 120. Reconstitution of plasticized material can occur defining a hollow-interior extruded structure 118 (also referred to as an “extrusion product” or an “extrudate”), such as can include one or more desired characteristics. Such characteristics can include grain structure or texture that are established using the extrusion through the die face orifice 138 or during down-stream processing such as controlled-temperature processing (e.g., quenching, annealing, or the like). Use of such down-stream processing is optional, and specified microstructure or other physical characteristics can be established using shear-assisted processing alone.

The mandrel 116 can be a part of the billet holder assembly 112 and can be in close proximity to the die face 128 (but can even be a portion of the die assembly as shown in other examples herein). Together with a die face orifice 138 in the die face 128, the mandrel 116 can form an annular extrusion aperture (e.g., annular extrusion aperture 137 shown in FIG. 4 for case of illustration) that the plasticized extrusion material is extruded through to form the extruded structure 118. The extrusion aperture can be formed when the mandrel 116 is extended through a die face orifice 138 in the die face 128. While the mandrel 116 is illustrated as protruding through a center of the billet material 120, examples are not so limited. One such other example of the mandrel 116 being rigidly affixed to the die face 128 is illustrated in FIG. 2.

FIG. 1B illustrates, by way of example and not limitation, a system 100 for extruding a structure having a hollow cross section. FIG. 1B, while having similar components to the system 100 of FIG. 1A, can configured to operate in a different way from the system 100 of FIG. 1A. For example, FIG. 1B illustrates an example of a die assembly 110 that moves or translates axially along the longitudinal axis 135 and a container sidewall 112B and container base 112A (of the billet holder assembly 112) that can rotate about the longitudinal axis 135. In this way, the die assembly 110 can provide movement to establish the axial extrusion force and the container provides movement to establish the rotation-induced shearing force. Such movement can be helpful to inhibit or prevent certain aspects of the extrusion system from rotating. For example, the extruded structure 118 in FIG. 1A can be extruded into the internal portion 111 within the die assembly 110 that is rotating. For this reason, the extruded structure 118 may be rotating within the die assembly 110 as well as the extruded structure 118 is being extruded. The rotation of the extruded structure 118 can cause malformation or warp when extruding extrudates of a particular shape. An extruded structure 118 with a non-circular shape may be more susceptible to such warping or malformation if it is rotating such as in FIG. 1A.

While the illustrations of FIG. 1A and FIG. 1B indicate total axial movement or total rotational movement from either the die assembly 110 or the container, examples are not so limited. A majority of the axial movement can occur with the die assembly 110 or a majority of rotational movement can occur with the container while the container may also have slight or lesser axial movement and/or the die may have slight or lesser rotational movement. That is, the die assembly 110 and the billet holder assembly 112 can move to a lesser degree within the discussed and shown range of movement. For example, one or more of the die assembly 110 or the 120 can move for or within a portion of their range of motion.

FIG. 2 illustrates, by way of example and not limitation, a system for extruding a structure having a hollow cross section. The system can include a die holder 121, a die shank 114, and a die face 128. The die holder 121, the die shank 114, and the die face 128 can be fixed to each other and can rotate (as the die assembly 110 rotates) about the longitudinal axis 135. The system can include a container base 112A and a container sidewall 112B that can be used to hold a billet material 120. As shown in FIG. 2, a liner 132 can be in direct contact with the billet material 120 and the container sidewall 112B. In some examples, the billet material 120 can be in direct contact with the container sidewall 112B without a liner 132.

The die face 128 can be part of a porthole die 122. The porthole die 122 can include portholes 117. The porthole die 122 can include a mandrel 116 that extends from the die face 128. The die face 128, porthole die 122, and mandrel 116 can move longitudinally (can translate) along the longitudinal axis 135, either away from or toward the billet material 120. Further the porthole die 122 can move rotationally around the longitudinal axis 135. In the alternative, the billet material 120 and/or container (112A/112B) can move rotationally around and/or axially along the longitudinal axis 135. Variations of such movement are discussed further below in association with FIGS. 4-7. Whichever way such movement occurs, as the die face 128 and billet material 120 can establish rotational shear and the axial extrusion force on the billet material 120, such that the billet material 120 can plasticize and be extruded through holes in the porthole die 122. The plasticized billet material extruded through the holes of the porthole die 122 can be extruded to surround the mandrel 116 behind the porthole die 122 and form an extruded structure, as will be further described below. The extruded structure can be extruded through an internal portion 111 of the die shank 114.

In an example, the container base 112A can be replaced with a stem or ram device (see FIGS. 5-6 below) that provides direct extrusion of the billet material 120. For example, a stem or ram device could be used to translate the billet material 120 axially toward the die face 128. In this example, the die face 128 may remain stationary. Alternatively, or additionally, the die face 128 can be translated toward the billet material 120.

FIGS. 3A and 3B illustrate, by way of example and not limitation, respective top and bottom isometric views of a porthole die with a modified scroll face and mandrel. FIG. 3A illustrates a top isometric view of the porthole die 122 showing the modified scroll face and FIG. 3B illustrates a bottom isometric view of the porthole die 122 showing the portholes and a mandrel. Grooves 113 and 115 can extend into the die face 128 of the porthole die 122 surface 124, extending into the die from an outer surface. The Grooves 113 and 115 can help direct plasticized billet material toward the portholes 117. The threaded holes 123 can be used to attach the die face to the die shank.

Plasticized billet material can then pass through the portholes 117 and across the mandrel 116. In this illustrative example, material flow can be separated into four distinct streams through the four portholes 117, as the billet material 120 and the porthole die 122 are forced against one another due to rotational and axial movement. In other examples, more or fewer portholes can be used. As an illustration, the outer grooves 115 on the die face 128 can feed material inward toward the portholes 117, and inner grooves 113 on the die face 128 can feed material radially outward toward the portholes 117.

In this illustrative example, one groove 113 can feed material radially outward toward each aperture port 117 for a total of four outward flowing grooves. The outer grooves 115 on the die face 128 can feed material radially inward toward the aperture port 117. In this illustrative example, two grooves can feed material radially inward toward each aperture port 117 for a total of eight inward feeding grooves 115. In addition to these two sets of grooves, the die 122 can include a perimeter scrolled groove 119 located radially or laterally outward on an outer perimeter surface 125 of the porthole die 122, shown in FIG. 3B. The perimeter scrolled groove 119 is oriented counter to the die rotation so as to provide back pressure thereby minimizing material flash between the liner 132 (or, in the absence of a liner, the container sidewall 112B) and die assembly 110 during extrusion.

In FIG. 3B, the porthole die 122 shows a series of full penetration of portholes 117. In use, streams of plasticized billet material can be directed by the inward 115 and outward 113 grooves described above can pass through these portholes 117 and can then be recombined and flow around a mandrel 116 to create a desired cross section. In this way, the grooves 113, 115, and 119 can be used to feed the portholes 117 during rotation to separate material flow of the feedstock (e.g., powder, flake, or billet) into distinct flow streams. This arrangement can help to enable formation of extruded products with hollow cross sections and, depending on the porthole die 122 configuration, non-circular interior or exterior profiles (or both). Whichever setup is used, such as the mandrel illustrated in FIGS. 1A-1B, the porthole die configuration in FIGS. 3A-3B, or additional configurations not illustrated, the variation of rotational and/or axial movements described herein can be used with any number of die face configurations and/or associated mandrels.

FIG. 4A illustrates, by way of example and not limitation, a section view of a portion of a system 100 including a container assembly and die assembly 110 for extruding hollow cross section pieces using an indirect extrusion technique or process with canister translation. The section view of the portion of the system of FIG. 4A can be an enlarged or focused section view from what is illustrated in FIG. 2. The portion of the system 100 can include the die shank 114 and the die face 128. The die shank 114 and the die face 128 can be fixed or connected to each other. The system can include the container base 112A and the container sidewall 112B used to hold the billet material 120. As illustrated, the liner 132 can be in direct contact with the billet material 120 and the container base 112A, as discussed above in FIG. 2.

As shown by the rotating arrow R in FIG. 4A, the container 112 can rotate about the longitudinal axis 135. The die assembly 110 can be rotationally stationary with respect to the billet material and the container components (e.g., 120, 132, 120 and 112). Further, as shown by the left-to-right arrow T, the container assembly 112 can move axially along the longitudinal axis 135. The die and die face 128 can be axially stationary, relative to the container. In this way, movement of the billet system (e.g., container sidewall 112B, container base 112A, and/or billet material 120) can provide the movement for the axial extrusion force and the rotation-induced shear force. In FIG. 4A, the container base 112A can be fixed relative to the container sidewall 112B and the billet material 120, and subsequent billet materials being used, can be inserted or removed from the left side of the illustration of the billet system through an opening 127.

The die face 128 can be part of a porthole die (e.g., porthole die 122 in FIG. 3B) wherein the porthole die includes a mandrel 116 that extends outward from the die face 128. The die face 128 and mandrel 116 (with the die assembly 110) can be rotationally stationary and axially stationary. The billet system can move axially along the longitudinal axis, either away from or toward the die face 128. As the billet system approaches the die face 128, the rotational and axial motion can establish shear at an interface between the billet material 120 and the die face 128, causing the billet material 120 to plasticize and be extruded through holes in the porthole die 122.

FIG. 4B illustrates, by way of example and not limitation, a section view of a portion of a system 100 including a die tool and a billet for extruding hollow cross section pieces using a shear-assisted indirect extrusion technique or process with canister translation. The system 100 of FIG. 4B can be configured similarly to the system 100 of FIG. 4A; the system 100 of FIG. 4B can include a translating die assembly.

For example, as shown by the rotating arrow R in FIG. 4B, the billet holder assembly 112 (e.g., including the container base 112A, the container sidewall 112B, and the liner 132) and the billet material 120 can rotate about the longitudinal axis 135. The die assembly 110 and the die face 128 can be rotationally stationary with respect to the billet material and the container components (e.g., 112A and 112B). As further shown by the left-to-right arrow T, the die assembly 110 can move axially along the longitudinal axis 135 and the container base 112A, the container sidewall 112B, and the billet material 120 can be axially stationary, relative to the die. In this way, the billet system (e.g., container sidewall 112B, container base 112A, and/or billet material 120) can provide rotation for the rotation-induced shear force and the die assembly can provide translation for the axial extrusion force. In FIG. 4B, the container base 112A can be fixed relative to the container sidewall 112B and the billet material 120, and subsequent billet materials being used, can be inserted or removed from the left side of the illustration of the billet system through an opening 127.

The die assembly 110 (and the mandrel 116) can be rotationally stationary but can translate (move axially) along the longitudinal axis, either away from or toward the container 112B and the billet material 120. As the die face 128 approaches the billet system, the rotational and axial motion can establish shear at an interface between the billet material 120 and the die face 128, causing the billet material 120 to plasticize and be extruded through holes in the porthole die 122 in an indirect extrusion process.

FIG. 5 illustrates, by way of example and not limitation, a section view of a portion of a system 100 including a die tool and a billet for extruding hollow cross section pieces. System 100 can be similar to the system 100 of FIG. 2 but can perform a shear-assisted direct extrusion process. The system 100 can include a die shank 114, and a die face 128. The die shank 114 and the die face 128 can be connected to, coupled to, or fixed to each other. The system 100 can also include the container sidewall 112B used to hold the billet material 120. The liner 132 can be connected to the container sidewall 112B and can be located on a radially inner portion thereof such that the liner 132 is in direct contact with the billet material 120 and the container sidewall 112B. In some examples, the liner 132 can be excluded and the billet material 120 can be in direct contact with the container sidewall 112B.

The system 100 can also include a ram 136. The ram 136 can be connected to a shaft 140 such that the ram 136 and the shaft 140 translate or rotate together. The ram 136 can be configured (e.g., sized or shaped) to fit within an inner diameter of the liner 132 (or the container sidewall 112B when the liner 132 is not included) such that the ram 136 can form a relatively tight seal between the ram 136 and the liner 132. The ram 136 can be configured to contact the billet material 120 such as to push the billet material 120 through the container (e.g., through the inside of the liner 132 or container sidewall 112B) and translate axially along the longitudinal axis 135 toward the die face 128. The billet material 120 can be inserted through either end of the container, such as the opening 127 or an opening 142 opposite the opening 127. The opening 142 can be sized and shaped to receive the ram (and the shaft 140) therein or therethrough. Also, between extrusion operations, one or more of the ram 136 and the billet holder assembly 112 can be axially moved (right) away from the die assembly 110, such as to facilitate cleaning, changing of dies, etc. However, during extrusion, the billet holder assembly 112 can be fixed, as discussed.

As shown by the rotating arrow R2 alongside the ram 136 and the rotating arrow R1 above the container sidewall 112B, the ram 136 and the billet system (e.g., container sidewall 112B, billet material 120) can rotate about the longitudinal axis 135. Further, as shown by the left-to-right arrow T alongside the ram 136, the ram 136 and the shaft 140 can move axially along the longitudinal axis 135. Optionally, the ram 136 can move axially independent of axial movement by the billet system. The billet system can remain axially stationary with respect to the die face 128. In this way, movement of the ram 136 and the billet system and the ram 136 can provide the movement for the rotation-induced shear force and translation of the ram 136 can provide the translation for the axial extrusion force. The rotation speed of the billet system and the rotation speed of the ram 136 can be approximately the same rotation speed which can help to reduce friction when their rotational speed is not synchronized. For example, a different speed of rotation of the ram 136 than the billet system can cause the interface of the ram 136 and the billet material 120 to create friction and possibly heat at the wrong interface.

The die face 128 can be part of a porthole die (e.g., porthole die 122 in FIG. 3B) wherein the porthole die includes a mandrel 116 that extends outward from the die face 128. The die face 128 and mandrel 116 can be rotationally stationary and axially stationary with respect to the billet system. The ram 136 and the billet material 120 can move axially along the longitudinal axis, either away from or toward the die face 128. As the billet material 120 approaches the die face 128, the rotational and axial motion can establish shear at an interface between the billet material 120 and the die face 128, causing the billet material 120 to plasticize and be extruded through holes in the porthole die 122.

Optionally, the system 100 can include a dummy block 144 that can be connected to an end portion of the ram 136, such as between the billet material 120 and the ram 136 so that the dummy block 144 contacts the billet material 120. The dummy block 144 can be held in place by a geometric interface or by friction between the billet material 120 and the ram 136 such that the dummy block 144 rotates and translates with the ram 136. Such a connection type can allow for the dummy block 144 to be easily removed or replaced. The dummy block 144 can be made of one or more of polymers, ceramics, metals, graphite, or the like, and can be configured to wear such that the dummy block 144 can be replaced at a lower expense or cost than replacement of a portion of the canister or ram.

FIG. 6 illustrates, by way of example and not limitation, a section view of a portion of a system 100 including a die tool and a billet for extruding hollow cross section pieces using a shear-assisted direct extrusion process or technique. The section 100 can be similar to the systems 100 discussed above. The system 100 can include the die assembly 110. The system 100 can also include the container sidewall 112B used to hold the billet material 120. The liner 132 can be connected to a radially inner surface of the container sidewall 112B such that the liner 132 can be in direct contact with the billet material 120 and the container sidewall 112B. Optionally, the liner 132 can be excluded.

The system 100 can also include the shaft 140 connected to an outer or distal portion of the ram 136. The ram 136 can also be in contact with the billet material 120. The shaft 140 can be drivable to drive the ram 136 to push or translate the billet material 120 through the container (e.g., through the inside of the liner 132 or container sidewall 112B) and can move axially along the longitudinal axis 135 toward the die face 128.

As shown by the rotating arrow R, the die assembly (e.g., die assembly 110 in FIG. 2) and die face 128 can rotate about the longitudinal axis 135. The die and die face 128 can rotate independent or relative to rotation of the billet system (e.g., independent of rotation of the container sidewall 112B, the billet material 120). The billet system can remain rotationally stationary with respect to the die face 128 and the die shank 114. Further, as shown by the left-to-right arrow T, the ram 136 can move axially along the longitudinal axis (e.g., longitudinal axis 135 in FIG. 2). The ram 136 can move axially independent of axial movement by the billet system such that the ram 136 can move or translate relative to the container sidewall 112B and the billet material 120. The billet system can remain axially stationary with respect to the die face 128. Therefore, the billet system can remain stationary both axially and rotationally. In this way, movement of the die and die face 128 can provide the rotation to create a shear force and translation of the ram 136 can generate or create the axial extrusion force during a direct extrusion process or technique.

The die face 128 can be part of a porthole die (e.g., porthole die 122 in FIG. 3B) wherein the porthole die includes a mandrel 116 that extends outward from the die face 128. The die face 128 and mandrel 116 can be axially stationary with respect to the container system. The ram 136 and the billet material 120 can move axially along the longitudinal axis, either away from or toward the die face 128. As the billet material 120 approaches the die face 128, the rotational and axial motion can establish shear at an interface between the billet material 120 and the die face 128, causing the billet material 120 to plasticize and be extruded through holes in the porthole die 122.

FIG. 7A illustrates, by way of example and not limitation, a section view of a portion of a system 100 including a die tool and a billet for extruding hollow cross section pieces using a shear-assisted indirect extrusion process or technique with a stationary canister. The system 100 of FIG. 7A can be similar to the systems 100 discussed above.

The system 100 can include the die shank 114 and the die face 128 that can be connected or fixed to each other. The system 100 can also include the container base 112A and the container sidewall 112B configured to hold or support the billet material 120 at least partially therein. As illustrated, the liner 132 can be connected to a radially inner portion of the container sidewall 112B such that the liner 132 can be in direct contact with the billet material 120 and the container base 112A. In other examples, the liner 132 can be excluded.

As shown by the rotating arrow R, the die assembly 110 and the die face 128 can rotate about the longitudinal axis 135. Further, as shown by the left-to-right arrow, the die assembly 110 can translate or move about the longitudinal axis 135. The billet system (e.g., the container sidewall 112B, the container base 112A, and the billet material 120) can be rotationally stationary or not rotate about the longitudinal axis 135 and the billet system can be axially stationary. In this way, movement of the die and die face 128 can provide the movement for the axial extrusion force and the rotational shearing force to perform an indirect shear-assisted extrusion process or technique.

In this particular illustrated example of FIG. 7A, the container base 112A can be fixed and the billet material 120, and subsequent billet materials being used, can be inserted or removed from the left side of the illustration of the billet system through the opening 127. The die face 128 can be part of a porthole die (e.g., porthole die 122 in FIG. 3B) wherein the porthole die includes the mandrel 116 that extends outward from the die face 128. The billet system can be rotationally stationary and axially stationary. The die face 128 can move axially along the longitudinal axis, either away from or toward the die face 128. As the die face 128 approaches the billet material 120, the rotational and axial motion can establish shear at an interface between the billet material 120 and the die face 128, causing the billet material 120 to plasticize and be extruded through holes in the porthole die 122.

FIG. 7B illustrates, by way of example and not limitation, a section view of a portion of a system 100 including a die tool and a billet for extruding hollow cross section pieces using a shear-assisted indirect extrusion process or technique with a translating canister. The system 100 of FIG. 7B can be similar to the systems 100 discussed above.

As shown by the rotating arrow R, the die assembly 110 and the die face 128 can rotate about the longitudinal axis 135 such as relative to the billet system (e.g., the container sidewall 112B, the container base 112A, and the billet material 120) and the billet system can be rotationally stationary. Further, as shown by the left-to-right arrow, the billet system can translate or move about the longitudinal axis 135 and the die assembly 110 can be axially stationary. In this way, movement of the die and die face 128 can provide the movement for the axial extrusion force and the rotational shearing force to perform an indirect shear-assisted extrusion process or technique.

That is, the billet system can be rotationally stationary and can translate axially along the longitudinal axis, either away from or toward the die face 128. The die face 128 can rotate about the longitudinal axis 135 but can be axially stationary. As the die face 128 approaches the billet material 120, the rotational and axial motion can establish shear at an interface between the billet material 120 and the die face 128, causing the billet material 120 to plasticize and be extruded through holes in the porthole die 122.

FIG. 8 illustrates a schematic view of the method 800, in accordance with at least one example of this disclosure. The method 800 can be a method of performing shear-assisted extrusion for extruding hollow cross-section pieces. More specific examples of the method 800 are discussed below. The steps or operations of the method 800 are illustrated in a particular order for convenience and clarity; many of the discussed operations can be performed in a different sequence or in parallel without materially impacting other operations. The method 800 as discussed includes operations performed by multiple different actors, devices, or systems. It is understood that subsets of the operations discussed in the method 800 can be attributable to a single actor, device, or system could be considered a separate standalone process or method.

The method 800 may be carried out using an extrusion system such as the systems described in association with FIGS. 1 to 7. Various examples are illustrated in the figures above. One or more features from one or more of these examples may be combined to form other examples.

At 802, the method 800 can include establishing a rotation-induced shear force and an axial extrusion force at an interface where a face of a die tool engages with a face of a portion of billet or other feedstock material. The rotation-induced shear force can be established by rotating the die tool or rotating the portion of feedstock material, such as by rotating the canister. When rotating the die tool, the portion of feedstock can be rotationally stationary. When rotating the portion of feedstock material, the die tool can be rotationally stationary. The container that holds the feedstock material can be rotated with the feedstock material. The axial extrusion force can be established by movement of the die tool along a longitudinal axis of the die tool or by movement of the portion of feedstock material along the longitudinal axis. When moving the die tool axially, the portion of feedstock can be axially stationary. The die tool can move axially toward the feedstock material. When moving the portion of feedstock material axially, the die tool can be axially stationary.

The portion of feedstock material can be moved axially by a ram in contact with the feedstock material. The portion of feedstock material can move axially at a different rate than the container. The portion of feedstock material can move axially independent of axial movement of the container. The container can include an opening at a first end of the container opposite a second end nearer the die tool and the ram can move along a longitudinal axis of the container through the opening at the first end to establish the axial extrusion force. The feedstock material can rotate at about a same speed of rotation as the ram or within a threshold speed of rotation of the ram.

At 804, the method 800 can include extruding the portion of feedstock material through an opening of the die tool in response to establishing the rotation-induced shear force and the axial extrusion force. The die tool can be rotated at a different rate than the feedstock material prior to extrusion of the feedstock material through the opening of the die tool. The portion of feedstock material can be extruded over a mandrel and the mandrel can be rotated at a rate different than the billet or other feedstock material during the extrusion. The mandrel can be rotationally stationary during the extrusion. The die tool can include a porthole die and the portion of feedstock material can be extruded through the porthole die while the porthole die is rotated at a rate different than the billet or other feedstock material. The extrusion of the portion of feedstock material can result in an extruded product and the extruded product may not rotating while being extruded.

The rotation-induced shear force and axial extrusion force can generate heat within the portion of feedstock material at or nearby an opening of a die face of the die tool. The generated heat can plasticize the portion of feedstock material at or nearby the opening and at least a portion of the feedstock material can be extruded without forming a liquid phase.

This process can help enable better strength, ductility, and corrosion resistance at the macroscopic level together with increased and better performance. This process can help reduce or eliminate the need for additional heating. The process can use any of a variety of forms of material including billet, powder, or flake without the need for extensive preparatory processes such as “steel canning”, billet preheating, de-gassing, de-canning, or the like. This arrangement can also help provide a methodology for performing other steps such as cladding, enhanced control for through wall thickness and other characteristics, joining of dissimilar materials and alloys, and may be used to provide feedstock materials for subsequent operations such as rolling.

As discussed above, ShAPE generally involves engagement of a die tool with a billet material as a feedstock to produce an extrudate. For example, the die tool can use spiral grooves on a die face to feed material inward through a die and around a mandrel that is traveling in the same direction as the extrudate. As such, a much larger outer diameter and extrusion ratio are possible as compared to other approaches, the material has a controlled wall thickness, the extrudate is free to push off the mandrel as in other extrusion techniques, and the extrudate length is limited only by feedstock volume. Accordingly, ShAPE can be scaled to suit higher-volume production.

The method examples described herein may be machine or computer-implemented at least in part. Some examples may include a computer-readable medium or machine-readable medium encoded with instructions operable to configure an electronic device or system to perform methods as described in the above examples. An implementation of such methods may include code, such as microcode, assembly language code, a higher-level language code, or the like. Such code may include computer readable instructions for performing various methods. The code may form portions of computer program products. Further, the code may be tangibly stored on one or more volatile or non-volatile computer-readable media during execution or at other times.

NOTES AND EXAMPLES

The following, non-limiting examples, detail certain aspects of the present subject matter to solve the challenges and provide the benefits discussed herein, among others.

Example 1 is a method can include establishing a rotational shearing force and an axial extrusion force at an interface where a face of a die tool engages with a face of a portion of billet or other feedstock material; and extruding the portion of feedstock material through an opening of the die tool in response to establishing the rotational shearing force and the axial extrusion force; wherein the die tool is rotated at a different rate than the feedstock material prior to extrusion of the feedstock material through the opening of the die tool.

In Example 2, the subject matter of Example 1 optionally includes wherein the die tool is rotationally stationary.

In Example 3, the subject matter of any one or more of Examples 1-2 optionally include wherein the rotational shearing force is established by rotation of the feedstock material.

In Example 4, the subject matter of Example 3 optionally includes wherein a container that contains the billet or feedstock material is rotated together with the feedstock material.

In Example 5, the subject matter of any one or more of Examples 1-4 optionally include wherein the axial extrusion force is established by movement of the die tool along a longitudinal axis of the die tool.

In Example 6, the subject matter of Example 5 optionally includes wherein the die tool moves along the longitudinal axis of the die tool toward the feedstock material and the feedstock material does not move along the longitudinal axis of the die tool.

In Example 7, the subject matter of any one or more of Examples 1-6 optionally include wherein the axial extrusion force is established by movement of the feedstock material along a longitudinal axis of the feedstock material toward the die tool.

In Example 8, the subject matter of Example 7 optionally includes wherein the feedstock material is moved along the longitudinal axis by a ram in contact with the feedstock material.

In Example 9, the subject matter of any one or more of Examples 7-8 optionally include wherein: a container contains the billet or other feedstock material; and the billet or other feedstock material moves along the longitudinal axis of the billet or other feedstock material at a different rate than the container.

In Example 10, the subject matter of any one or more of Examples 8-9 optionally include wherein the billet or other feedstock material is moved along the longitudinal axis by the ram independent of movement of a container along the longitudinal axis, wherein the container contains the billet or other feedstock material.

In Example 11, the subject matter of any one or more of Examples 1-10 optionally include wherein the portion of billet or other feedstock material is extruded over a mandrel and the mandrel is rotated at a rate different than the billet or other feedstock material during the extrusion.

In Example 12, the subject matter of Example 11 optionally includes wherein the mandrel is rotationally stationary during the extrusion.

In Example 13, the subject matter of any one or more of Examples 1-12 optionally include wherein the die tool comprises a porthole die and the portion of billet or other feedstock material is extruded through the porthole die while the porthole die is rotated at a rate different than the billet or other feedstock material.

In Example 14, the subject matter of any one or more of Examples 1-13 optionally include wherein the extrusion of the billet or other feedstock material results in an extruded product and the extruded product is not rotating while being extruded.

Example 15 is a method for shear-assisted extrusion, the method comprising: establishing a rotational shearing force at an interface between a die tool and a portion of billet or other feedstock material by rotating the billet or other feedstock material and without requiring rotation of the die tool; establishing an axial extrusion force at the interface; and extruding the portion of billet or other feedstock material through an opening of the die tool in response to application of the rotational shearing force and the axial extrusion force.

In Example 16, the subject matter of Example 15 optionally includes wherein the axial extrusion force is established at the interface by movement of the portion of the billet or other feedstock material along a longitudinal axis of the billet or other feedstock material.

In Example 17, the subject matter of any one or more of Examples 15-16 optionally include wherein a container that contains the billet or other feedstock material comprises an opening at a first end opposite a second end nearer the die tool and a ram is configured to move along a longitudinal axis of the container through the opening at the first end to establish the axial extrusion force.

In Example 18, the subject matter of Example 17 optionally includes wherein the billet or other feedstock material rotates at a same speed as or rotation or within a threshold speed of rotation at about a same speed of rotation as the ram.

In Example 19, the subject matter of any one or more of Examples 15-18 optionally include wherein the axial extrusion force is established, at least partially, by movement of the die tool along a longitudinal axis of the die tool and toward the portion of the billet or other feedstock material.

Example 20 is a method for shear-assisted extrusion, the method comprising: establishing a rotational shearing force at an interface between a die tool and a portion of billet or other feedstock material within a container by rotating the container and the billet or other feedstock material and without requiring rotation of the die tool; establishing an axial extrusion force at the interface by movement of one of the die tool or the container along a longitudinal axis of the container; and extruding the portion of billet or other feedstock material through an opening of the die tool in response to application of the rotational shearing force and the axial extrusion force; wherein the extruded portion of billet or other feedstock material is not rotated while extruded.

Example 24 is a method for shear-assisted extrusion, the method comprising: establishing rotational shear at an interface where a face of a die tool engages with a face of a portion of feedstock material supported by a container by rotating the die tool at a different rate than the feedstock material; and extruding the portion of the feedstock material through an opening of the die tool using plastic deformation of the portion of the feedstock material established by the rotational shear at the interface and an axial extrusion force.

In Example 25, the subject matter of Example 24 optionally includes rotating the die tool relative to the container and the feedstock material to establish the rotational shear; and translating the die tool relative to the container and the feedstock material to establish the axial extrusion force.

In Example 26, the subject matter of Example 25 optionally includes maintaining a rotational position of the container during extruding.

In Example 27, the subject matter of any one or more of Examples 25-26 optionally include maintaining a rotational position of the feedstock material during extruding.

In Example 28, the subject matter of any one or more of Examples 25-27 optionally include maintaining a rotational position of a ram during extrusion, the ram directly or indirectly engaged with the feedstock material to apply the axial extrusion force.

In Example 29, the subject matter of any one or more of Examples 24-28 optionally include rotating the die tool relative to the container and the feedstock material to establish the rotational shearing force.

In Example 30, the subject matter of Example 29 optionally includes maintaining a rotational position of the container during extruding.

In Example 31, the subject matter of any one or more of Examples 29-30 optionally include maintaining a rotational position of the feedstock material during extruding; and translating the feedstock material relative to the container and the die during extruding.

In Example 32, the subject matter of Example 31 optionally includes maintaining a rotational position of a ram during extruding; and translating the ram relative to the container and the die to translate the feedstock material relative to the container and the die to establish the axial extrusion force during extruding.

In Example 33, the subject matter of any one or more of Examples 31-32 optionally include extruding the portion of the feedstock material through the die tool opposite the ram.

In Example 34, the subject matter of any one or more of Examples 24-33 optionally include maintaining a rotational position of the die tool during extruding; and translating the die tool relative to the container and the feedstock material to establish the axial extrusion force.

In Example 35, the subject matter of Example 34 optionally includes rotating the container relative to the die tool to establish the rotational shear.

In Example 36, the subject matter of any one or more of Examples 34-35 optionally include rotating the feedstock relative to the die tool to establish the rotational shear; and maintaining an axial position of the feedstock relative to the container during extruding.

In Example 37, the subject matter of Example 36 optionally includes rotating a ram relative to the die tool to establish the rotational shear; and maintaining an axial position of the ram relative to the container during extruding.

In Example 38, the subject matter of any one or more of Examples 24-37 optionally include maintaining a rotational position of the die tool during extruding.

In Example 39, the subject matter of Example 38 optionally includes rotating the container relative to the die tool to establish the rotational shear.

In Example 40, the subject matter of any one or more of Examples 38-39 optionally include rotating the feedstock to establish the rotational shear; and translating the feedstock relative to the container during extruding to establish the axial extrusion force.

In Example 41, the subject matter of Example 40 optionally includes rotating a ram to rotate the ram to establish the rotational shear; and translating the ram relative to the container during extruding to establish the axial extrusion force.

In Example 42, the subject matter of any one or more of Examples 40-41 optionally include extruding the portion of the feedstock material through the die opposite the ram.

Example 43 is a system for shear-assisted extrusion, the system comprising: a container configured to support feedstock material at least partially therein; and a die tool configured to engage the feedstock material, the die tool defining an opening to receive the feedstock therethrough in response to a rotational shear and an axial extrusion force to form extrudate through the opening.

In Example 44, the subject matter of Example 43 optionally includes wherein the die tool is configured to rotate relative to the container and the feedstock material to establish the rotational shear, and wherein the die tool is configured to translate relative to the container and the feedstock material to establish the axial extrusion force.

In Example 45, the subject matter of any one or more of Examples 43-44 optionally include wherein the container is configured to maintain the feedstock in a fixed rotational position during extruding.

In Example 46, the subject matter of any one or more of Examples 43-45 optionally include wherein the system is configured to maintain the feedstock in a fixed rotational position during extruding.

In Example 47, the subject matter of any one or more of Examples 43-46 optionally include a ram configured to directly or indirectly engage with the feedstock material, the ram configured to maintain a fixed rotational position during extruding.

In Example 48, the subject matter of any one or more of Examples 43-47 optionally include wherein the die tool is configured to rotate relative to the container and the feedstock material to establish the rotational shear.

In Example 49, the subject matter of Example 48 optionally includes wherein the container is configured to maintain a fixed rotational position of during extruding.

In Example 50, the subject matter of any one or more of Examples 48-49 optionally include wherein the system is configured to maintain the feedstock material in a fixed rotational position during extruding, and wherein the system is configured to translate the feedstock material relative to the container and the die during extruding to establish the axial extrusion force.

In Example 51, the subject matter of Example 50 optionally includes a ram configured to directly or indirectly engage with the feedstock material, the ram configured to maintain a rotational position during extruding, and the ram configured to translate relative to the container and the die tool to translate the feedstock material during extruding to establish the axial extrusion force.

In Example 52, the subject matter of any one or more of Examples 43-51 optionally include wherein the die tool is configured to maintain a rotational position during extruding, and wherein the die tool is configured to translate relative to the container during extruding to establish the axial extrusion force.

In Example 53, the subject matter of Example 52 optionally includes wherein the container is configured to rotate relative to the die tool during extruding to establish the rotational shear.

In Example 54, the subject matter of any one or more of Examples 52-53 optionally include wherein the system is configured to rotate the feedstock material during extruding to establish the rotational shear, and wherein the system is configured to maintain an axial position of the feedstock material relative to the container during extruding.

In Example 55, the subject matter of Example 54 optionally includes a ram configured to directly or indirectly engage with the feedstock material, the ram configured to rotate relative to the die to establish the rotational shear, and the ram configured to maintain an axial position of the ram relative to the container during extruding.

In Example 56, the subject matter of any one or more of Examples 43-55 optionally include wherein the die tool is configured to maintain a rotational position during extruding.

In Example 57, the subject matter of Example 56 optionally includes wherein the container is configured to rotate relative to the die tool during extruding to establish the rotational shear.

In Example 58, the subject matter of any one or more of Examples 56-57 optionally include wherein the system is configured to rotate the feedstock material during extruding to establish the rotational shear, and wherein the system is configured to maintain an axial position of the feedstock material relative to the container during extruding.

In Example 59, the subject matter of Example 58 optionally includes a ram configured to directly or indirectly engage with the feedstock material, the ram configured to rotate relative to the die to establish the rotational shear, and the ram configured to maintain an axial position of the ram relative to the container during extruding.

In Example 60, the apparatuses or method of any one or any combination of Examples 1-59 can optionally be configured such that all elements or options recited are available to use or select from.

The above detailed description includes references to the accompanying drawings, which form a part of the detailed description. The drawings show, by way of illustration, specific embodiments in which the invention can be practiced. These embodiments are also referred to herein as “examples.” Such examples can include elements in addition to those shown or described. However, the present inventors also contemplate examples in which only those elements shown or described are provided. Moreover, the present inventors also contemplate examples using any combination or permutation of those elements shown or described (or one or more aspects thereof), either with respect to a particular example (or one or more aspects thereof), or with respect to other examples (or one or more aspects thereof) shown or described herein.

In the event of inconsistent usages between this document and any documents so incorporated by reference, the usage in this document controls. In this document, the terms “including” and “in which” are used as the plain-English equivalents of the respective terms “comprising” and “wherein.” Also, in the following claims, the terms “including” and “comprising” are open-ended, that is, a system, device, article, composition, formulation, or process that includes elements in addition to those listed after such a term in a claim are still deemed to fall within the scope of that claim.

In this document, the terms “a” or “an” are used, as is common in patent documents, to include one or more than one, independent of any other instances or usages of “at least one” or “one or more.” In this document, the term “or” is used to refer to a nonexclusive or, such that “A or B” includes “A but not B,” “B but not A,” and “A and B,” unless otherwise indicated. In this document, the terms “including” and “in which” are used as the plain-English equivalents of the respective terms “comprising” and “wherein.” Also, in the following claims, the terms “including” and “comprising” are open-ended, that is, a system, device, article, composition, formulation, or process that includes elements in addition to those listed after such a term in a claim are still deemed to fall within the scope of that claim. Moreover, in the following claims, the terms “first,” “second,” and “third,” etc. are used merely as labels, and are not intended to impose numerical requirements on their objects.

The above description is intended to be illustrative, and not restrictive. For example, the above-described examples (or one or more aspects thereof) may be used in combination with each other. Other embodiments can be used, such as by one of ordinary skill in the art upon reviewing the above description. The Abstract is provided to comply with 37 C.F.R. § 1.72(b), to allow the reader to quickly ascertain the nature of the technical disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. Also, in the above Detailed Description, various features may be grouped together to streamline the disclosure. This should not be interpreted as intending that an unclaimed disclosed feature is essential to any claim. Rather, inventive subject matter may lie in less than all features of a particular disclosed embodiment. Thus, the following claims are hereby incorporated into the Detailed Description as examples or embodiments, with each claim standing on its own as a separate embodiment, and it is contemplated that such embodiments can be combined with each other in various combinations or permutations. The scope of the invention should be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled.

	Number	Date	Country
	63530733	Aug 2023	US
	63604041	Nov 2023	US

SHEAR-ASSISTED EXTRUSION CONFIGURATIONS

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