Shear-assisted extrusion apparatus, tools, and methods

Abstract

Shear-assisted extrusion devices, tools, inserts, and / or methods are provided. The devices may include an extrusion receiving channel operably engaged with the tool to receive the extruded material and one or more openings aligned between the ends of the spindle and configured to deliver a fluid to the extruded product. An exemplary tool may include one or more openings aligned between the ends of the tool. An exemplary method may include quenching the plasticized feed material prior to exiting the spindle. A spindle assembly and / or tool assembly insert is also provided, which may include a sleeve extending into one or both of the spindle assembly or tool assembly of the device and an opening in the sleeve configured to deliver a fluid into one or both of the receiving channels of the spindle assembly or the tool assembly.

Description

[Technical Field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims priority to U.S. Patent Application No. 17 / 857,951, filed July 5, 2022, which is related to a continuation-in-part U.S. Patent Application No. 17 / 473,178, filed September 13, 2021, entitled "Devices and Methods for Performing Shear-Assisted Extrusion and Extrusion Processes," each of which is incorporated by reference herein in its entirety.

[0002] STATEMENT OF RIGHTS TO INVENTIONS MADE UNDER FEDERALLY SPONSORED RESEARCH AND DEVELOPMENT This invention was made with government support under Contract No. DE-AC05-76RL01830 awarded by the U.S. Department of Energy. The U.S. Government has certain rights in this invention.

[0003] Technical Field FIELD OF THE DISCLOSURE This disclosure relates generally to metals technology, and more specifically to extrusion technology. [Background technology]

[0004] The growing need for fuel efficiency in transportation, coupled with ever-increasing needs for safety and regulatory compliance, has focused attention on the development and utilization of new materials and processes. Often, barriers to entry into these fields are caused by a lack of effective and efficient manufacturing methods. For example, the ability to replace steel automotive parts with materials made from magnesium or aluminum or their related alloys has attracted significant interest. Furthermore, the ability to form hollow parts with strengths equal to or greater than those of solid parts is a further desirable goal. Previous attempts have failed or been limited by a variety of factors, including the lack of suitable manufacturing processes, the expense of using rare earth elements in alloys to impart desired properties, and the high energy costs of manufacturing.

[0005] There is a need for methods and apparatus that allow for the production of articles, such as parts in automobiles or aerospace vehicles, having hollow sections made from raw materials such as magnesium or aluminum, with or without rare earth metals. There is also a need for processes and systems for the production of such articles that are more energy efficient, easier to implement, and produce materials with desired grain size, structure, and orientation so as to maintain strength and provide sufficient corrosion resistance. There is also a need for simplified processes that allow for the formation of such structures directly from billet, powder, or flake material without the need for additional processing steps. There is also a need for methods and related apparatus that reduce or eliminate the need for energy-intensive heat treatment steps before and / or after extrusion. There is also a need for new methods for forming high-entropy alloy materials that are simpler and more effective than current processes. The present disclosure provides a description of significant advances in meeting these needs.

[0006] Over the past several years, researchers at Pacific Northwest National Laboratory have developed a novel shear-assisted processing and extrusion (ShAPE) technology that uses a rotating tool as a ram or die to receive an axially fed billet, rather than using an axially fed billet without rotation, as in conventional extrusion processes. As described below and in the previously cited, referenced, and incorporated patent applications, this process and associated equipment offer several significant advantages, including reduced power consumption, fewer and less demanding heat treatments, superior material properties, and a novel "solid-state" type forming process and machinery suite. The benefits of these processes and devices are envisioned for deployment in a variety of industries and applications, including, but not limited to, transportation, projectiles, high-temperature applications, structural applications, nuclear applications, and corrosion-resistant applications.

[0007] The present disclosure overcomes many of the deficiencies of the prior art by eliminating steps entirely and providing extruded materials of higher quality than those prepared from these prior art methods. Summary of the Invention [Means for solving the problem]

[0008] A shear-assisted extrusion apparatus is provided that includes a spindle assembly extending from a first end to a second end and configured to rotate about a distance between the first and second ends, a tool operably engaged with the spindle and defining the second end of the spindle assembly, the tool configured to act on a feedstock material with a shear force imparted by the spindle, an extrusion receiving channel operably engaged with the tool to receive the extruded material, and one or more openings aligned between the first and second ends and configured to convey a fluid to the extruded product.

[0009] A shear-assisted extrusion tool is also provided that includes a conduit extending from a first end to a second end, the first end defining a die face and configured to interact with a feed material, and the second end configured to operably couple to a spindle of a shear-assisted extrusion apparatus; and one or more openings aligned between the first end and the second end and configured to convey a fluid through an interior wall of the conduit and / or the die face.

[0010] A method of quenching a shear-assisted extrusion product is also provided, and may include providing a shear-assisted force to a die face operatively engaged with a spindle of a shear-assisted extrusion device; receiving plasticized feedstock from the die face; and quenching the plasticized feed material prior to exiting the spindle.

[0011] A spindle assembly and / or tool assembly insert is provided, the insert including: a sleeve extending into one or both of the spindle assembly or tool assembly of the device; and an opening in the sleeve configured to convey fluid into one or both of the receiving channels of the spindle assembly or tool assembly.

[0012] The devices, tools, inserts, and / or methods of the present disclosure are exemplary configurations and are not intended to be exhaustive of all contemplated configurations.

[0013] Embodiments of the present invention will now be described with reference to the accompanying drawings, in which: [Brief explanation of the drawings]

[0014] [Figure 1] FIG. 1 illustrates a portion of a shear-assisted extrusion apparatus according to one embodiment of the present disclosure. [Figure 2] FIG. 2 illustrates another configuration of a portion of a shear-assisted extrusion device according to one embodiment of the present disclosure. [Figure 3] FIG. 3 is a more detailed view of a portion of a shear-assisted extrusion apparatus according to one embodiment of the present disclosure. [Figure 4] FIG. 4 is a diagram of a portion of a shear-assisted extrusion device according to one embodiment of the present disclosure. [Figure 5] FIG. 5 is a shear-assisted extrusion device according to one embodiment of the present disclosure. [Figure 6] FIG. 6 is a more detailed view of a portion of a shear-assisted extrusion apparatus according to one embodiment of the present disclosure. [Figure 7] FIG. 7 is a perspective view of components of a shear-assisted extrusion device according to one embodiment of the disclosure. [Figure 8] FIG. 8 is a detailed view of a portion of a shear-assisted extrusion apparatus according to an embodiment of the present disclosure. [Figure 9] FIG. 9 is a detailed diagram of a shear-assisted extrusion device according to one embodiment of the present disclosure. [Figure 10] FIG. 10 illustrates components of a shear-assisted extrusion device having a quench insert therein, according to one embodiment of the present disclosure. [Figure 11] FIG. 11 is a detailed view of a portion of the engagement of a component of a shear assisted extrusion apparatus with a quench insert, according to one embodiment of the present disclosure. [Figure 12]FIG. 12 is a detailed view of some of the components of a shear assisted extrusion apparatus and the engagement of a quench insert according to one embodiment of the present disclosure. [Figure 13] FIG. 13 is a detailed diagram of the components of FIG. 12 according to one embodiment of the present disclosure. [Figure 14] FIG. 14 is a detailed diagram of the components of FIG. 13 according to an embodiment of the present disclosure. [Figure 15] FIG. 15 is a detailed diagram of the components of FIG. 14 according to one embodiment of the present disclosure. [Figure 16] 16 and 17 are both illustrations of different quench head configurations according to embodiments of the present disclosure. [Figure 17] 16 and 17 are both illustrations of different quench head configurations according to embodiments of the present disclosure. [Figure 18] FIG. 18 is a diagram of a quench assembly in a shear-assisted extrusion apparatus according to an embodiment of the present disclosure. [Figure 19] 19 and 20 are diagrams of a discharge assembly according to an embodiment of the present disclosure. [Figure 20] 19 and 20 are diagrams of a discharge assembly according to an embodiment of the present disclosure. DETAILED DESCRIPTION OF THE INVENTION

[0015] explanation The apparatus, tools, and methods of the present disclosure will be described with reference to FIGS. 1-20. Referring initially to FIG. 1, a portion of a shear-assisted extrusion apparatus 10 is shown, including a feed material 20 in a feed material container 24 and a shear-assisted extrusion tool 16, which includes a tool head 12 and a die face 14 extending to a shank 15. The shank 15 may be defined by a tube having an inner sidewall 19 and an outer sidewall 17. The tool 16 also includes a flange 18 that may be operably coupled to a spindle assembly, not yet shown. In this configuration, the tool 16 is a single piece. Other configurations of the tool 16 may be an assembly of multiple components. An exemplary tool assembly is shown herein. As shown, a rotational force and an axial force are applied to the tool head 12. The axial force may be applied from the tool onto the feed material, or alternatively, the axial force may be applied from the feed material onto the tool. According to an exemplary implementation, a shear-assisted extrusion process provides an extruded material 22 .

[0016] Referring now to FIG. 2 , a portion of the apparatus 10 is shown that includes a mandrel 26 that allows the feed material 20 to be fed into the die face 14 and / or tool 16. The mandrel 26 can extend to the die face 14, where the feed material is plasticized and the plasticized material continues as extruded material within the tool 16 to form the extruded material 22. Alternatively, the mandrel 26 can continue beyond the die face 14 and provide support for the extruded material within the tool 16 after formation at the die face 14. According to an exemplary implementation, the material 22 can take the shape of the mandrel 26. Extruded material containing non-circular, multi-cell profiles can also be formed using a porthole bridge tool / die configuration as an alternative to the illustrated mandrel approach.

[0017] 3, a cross-sectional view of FIG. 2 is provided including a mandrel 26 supporting feed material, also known as a billet 20, within a container 24. As shown, the tool 16 can include a die face 14 and a tool head 12, which provides extruded material 22 that is formed by the action of rotational and axial forces as shown.

[0018] Referring now to FIG. 4 , in accordance with an exemplary implementation, apparatus portion 40 is shown to include both tool 16 and spindle 42, which rotates about receiving channel 44. Importantly, receiving channel 44 is stationary or fixed relative to spindle 42. Spindle 42 operatively rotates tool 16 to provide the rotational force referred to herein, and extends from one end 92 where it couples with tool 16, e.g., at flange 18, and terminates at the other end 90 with the rest of the apparatus, allowing receiving channel 44 to be continuous as shown. Accordingly, interfaces 90 and 92 are shown that allow spindle 42 to rotate while channel 44 remains fixed. Alternatively, at interface 92 between flange 18 and spindle 42, components are fixed, thereby providing for rotation of tool 16 in accordance with rotation of spindle 42.

[0019] 4, passages 60 are provided in receiving channel 44 and passages 50 are provided in tool 16. As shown, openings 52 can enter the interior wall of tool 16 from these passages, and openings 62 can enter the interior wall of the receiving channel. A fluid, such as a coolant, can be provided in these passages. Examples of coolants include, but are not limited to, water, air, inert gas, liquid nitrogen, nitrogen mist, and / or quench oil.

[0020] 5, portions of the apparatus provided herein may be operatively engaged using a complete apparatus as shown. This exemplary apparatus is known as a "Friction Extrusion Machine" or "Shear Assisted Processing and Extrusion Machine," examples and operation of which are further provided in U.S. Patent Application No. 17 / 473,178, filed September 13, 2021 (U.S. Patent Application Publication No. 2021 / 0402471, published December 30, 2021), which is incorporated herein by reference in its entirety.

[0021] Referring now to FIG. 6 , according to one particular embodiment, the apparatus portion 110 can include a mandrel 26 supporting a feed material 20. The feed material 20 can engage the die face 14 in the tool head 12 and be plasticized to form the extrusion material 22. According to an exemplary implementation, fluid can be supplied in passages 70 or 72 through the spindle 42, which can include a spindle face plate, via the exterior of the spindle and / or through the flange 18 of the tool assembly 16. As described herein, the tool assembly 16 can include a tool or die holder 66 and a die 68. According to an exemplary implementation, the passages 50 are continuous, and fluid can be provided through openings 52 into the interior wall of the tool 16. FIG. 7 shows an exterior view of the spindle 42 coupled with the tool assembly 16 and mandrel 26. As shown, passages 70 / 50 and / or passages 72 / 50 provide fluid to the tool assembly 16.

[0022] 8 , another exemplary implementation of an apparatus portion 120 of a shear-assisted extrusion apparatus is shown, including a tool assembly 16 having a tool holder 66 operatively coupled to a tool / die 68. The tool / die 68 includes a die face 14 and a tool head 12. According to the exemplary implementation, a passageway 50 can extend through the holder 66, through a wall of the tool / die 68, and be in fluid communication with an opening 52 that enters the rear or support surface of the die face 14. In the head 12, the plasticized material forms, flows, and cools or quenches. As shown, the assembly 16 can include a coupler 122 that can be used to couple the tool / die 68 to the holder 66.

[0023] 9 , yet another implementation of a shear-assisted extrusion apparatus portion 130 is shown, including feed material 20 engaging die face 14 at tool head 12. According to an exemplary implementation, conduit 50 may extend through tool 68 and exit at opening 52 located on support or rear surface 90 of die face 14.

[0024] 10 , there is shown an assembly 200 including the tool assembly 16 operatively coupled to the spindle assembly 42, which includes the spindle face plate 100 coupled to the spindle 102, as shown. The spindle 102 is operatively engaged with the rotary union 104. Within the assembly 200 is the quench assembly 106. The quench assembly 106 may be part of these components and / or an insert into already assembled components. The spindle assembly 42 may include components that rotate axially about a distance between the ends of the spindle assembly, such as the distance between the tool assembly 16 and the rotary union 104, the distance between the face plate 100 and the rotary union 104, and / or the length of the spindle 102.

[0025] 11 , according to an exemplary implementation, fluid may be supplied via intake 66 into passage 60 formed between receiving channel 44 and sleeve 144 and directed to opening 62 in sleeve 144. As shown, sleeve 144 extends into rotary union 104 and continues through spindle 42.

[0026] 12-14 , and previously with reference to FIG. 10 , a quench assembly 106 is illustrated that may extend through the spindle 42 to the tool assembly 16. In certain embodiments, the assembly 106 may include a quench head 162. The quench head 162 may include a plurality of openings 62 that are in fluid communication with the passageway 60 between the sleeve 144 and the receiving channel 44. According to an exemplary implementation, the quench head 162 may be configured to receive the extrusion material 22 and may be aligned within the spindle face plate 100 adjacent the tool assembly 16. A sleeve 168 may be operatively engaged with the tool assembly 16 and extend from the tool holder 66 or quench head 162 to the support 90, forming a passageway 50 between the assembly 16 and the extrusion material 22. Thus, fluid may be supplied from the passageway 60 to the passageway 50 and discharged at the opening 52 in the tool assembly 16. As shown in FIG. 14, the spent or used fluid 54 is shown returning along the extrusion material 22 .

[0027] As shown in FIG. 15 , fluid 54 continues to flow with extruded material 22 in the direction of extrusion 150. Thus, the flow of fluid 54 may be further enhanced by fluid from openings 62. As shown in FIGS. 16 and 17 , openings 62 may be configured to direct the fluid flow around the extruded material but prevent the fluid flows from flowing toward each other. Thus, the fluid flows can be offset to form radial engagements 180 of various sizes. As shown, the radius of the radial engagement in FIG. 16 is smaller than the radius of the radial engagement shown in FIG. 17 .

[0028] 18, fluid may be provided through the mandrel 26 to a quench head 162 having openings 74 to quench the interior of the extruded material 22. The spent or used fluid 54 may continue to flow in the direction of extrusion.

[0029] 19 and 20, the fluid 54 can be collected for reuse at opening 190. Opening 190 can be part of a reservoir assembly to prevent the fluid 54 from continuing to flow with the extruded material, as shown in FIG. 20. This discharge can be recycled and then re-cooled and returned for future use.

Claims

1. 1. A shear assisted extrusion device comprising: a spindle assembly extending from a first end to a second end and configured to rotate about a distance between the first end and the second end; a tool or billet operably engaged with the spindle and defining the second end of the spindle assembly, the tool configured to engage a feed material using a shear force applied from the spindle; an extrudate receiving channel operably engaged with said tool for receiving extruded material; one or more openings aligned between the first end and the second end for conveying fluid to the extruded product; An apparatus comprising:

2. The device of claim 1 , wherein at least one of the openings is within the receiving channel.

3. The apparatus of claim 2 , further comprising a fluid conduit extending between the spindle and the receiving channel.

4. The apparatus of claim 1 , wherein at least one of the openings is in the tool.

5. The apparatus of claim 4 , wherein at least one of the openings in the tool extends through an interior wall of the tool.

6. The apparatus of claim 5 , wherein the inner wall of the tool supports a die face of the tool.

7. The apparatus of claim 4 further comprising a conduit extending between the spindle and the tool.

8. The apparatus of claim 1 , further comprising a space between the receiving channel and the spindle, the space being configured to provide fluid to the one or more openings.

9. The apparatus of claim 1 , further comprising a mandrel operably engaged with the tool and defining the one or more openings.

10. The device of claim 1 , further comprising at least one fluid outlet opening within the receiving channel.

11. 1. A shear assisted extrusion tool comprising: a conduit extending from a first end to a second end, the first end defining a die face and configured to engage a feed material, and the second end configured to operably couple to a spindle of a shear assisted extrusion device; one or more openings aligned between the first end and the second end and configured to convey fluid through the conduit and / or an inner wall of the die face; Provided with a tool.

12. 12. The tool of claim 11, wherein the tool defines a shank between the first end and the second end, the tool further comprising a passageway extending through the shank, the passageway being in fluid communication with one or more of the openings.

13. The tool of claim 12 , wherein the passageway extends between the first end and the second end of the shank.

14. The tool of claim 12 , wherein the one or more openings extend through an interior wall defined by the shank.

15. The tool of claim 11 , wherein the tool defines an interior portion of the die face, and wherein the one or more openings extend through the interior portion of the die face.

16. The tool of claim 15 , further comprising a passage in the conduit that is in fluid communication with the one or more openings extending through the interior portion of the die face.

17. The tool of claim 11 , further comprising a passageway in fluid communication with the one or more openings.

18. The tool of claim 17 , wherein the passageway is configured to operably couple with a fluid intake.

19. The tool of claim 18 , wherein the passageway is configured to operably couple with a spindle of a shear assisted extrusion tool.

20. 20. The tool of claim 19, wherein the second end of the conduit forms a flange, and the passageway extends through the flange.

21. 1. A method for quenching a shear-assisted extrusion product, comprising: providing a shear assist force to a die face operatively engaged with a shear assisted extrusion device; receiving plasticized feed material from said die face; and quenching said plasticized feed material prior to exiting the spindle. A method comprising:

22. 22. The method of claim 21, further comprising providing a fluid to the plasticized feed material to quench the plasticized feed material.

23. 23. The method of claim 22, wherein the fluid is provided to the plasticized feed material after it has passed the die face.

24. The method of claim 21 , wherein the fluid is provided through a tool that supports the die face.

25. The method of claim 21 , wherein the fluid is provided through a mandrel operably coupled to the die face.

26. The method of claim 22, further comprising providing a fluid to a receiving channel in the spindle.

27. 27. The method of claim 26, wherein the receiving channel operably engages a tool on the die face, further comprising providing fluid to an end of the receiving channel operably engaging the tool.

28. 27. The method of claim 26, wherein the receiving channel is in operative engagement with an outlet of the spindle, and further comprising providing fluid to an end of the receiving channel that is in operative engagement with the outlet of the spindle.

29. 23. The method of claim 22, further comprising draining the fluid through the receiving channel.

30. 30. The method of claim 29, wherein the ejection occurs external to the spindle.

31. 1. A quench insert for a shear assisted extrusion device, comprising: a sleeve extending into one or both of the spindle assembly or tool assembly of the apparatus; an opening in the sleeve configured to convey fluid into one or both of the receiving channels of the spindle assembly or the receiving channels of the tool assembly; An insert comprising:

32. 32. The insert of claim 31, further comprising a quench head operatively engaged with said sleeve and defining said opening.

33. 32. The insert of claim 31, further comprising an inlet operatively engaged with the sleeve.

34. 34. The insert of claim 33, wherein the inlet is operatively engaged with the sleeve outside of the spindle assembly.

35. 32. The insert of claim 31, further comprising a vent operatively engaged with the sleeve.

36. 36. The insert of claim 35, wherein the outlet is operatively engaged with the sleeve outside of the spindle assembly.

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