System and process for formation of extrusion structures

Abstract

An extrusion apparatus and process are disclosed that produce high-performance extrusion structures. The extrusion apparatus includes a shear tool that applies a rotational shear force and an axial extrusion force to the face of a billet material that plasticizes the billet material. Plasticized material is extruded through an extrusion die along the length of the inner bore of the shear tool which yields hollow and solid extrusion structures. The process refines the microstructures of the extrusion structures and extrusion materials.

Description

CROSS REFERENCE TO RELATED APPLICATION[0001]This is a Non-Provisional application that claims priority from U.S. Provisional Application No. 61 / 804,560 filed 22 Mar. 2013, which reference is incorporated herein in its entirety.STATEMENT REGARDING RIGHTS TO INVENTION MADE UNDER FEDERALLY-SPONSORED RESEARCH AND DEVELOPMENT[0002]This invention was made with Government support under Contract DE-AC05-76RLO-1830 awarded by the U.S. Department of Energy. The Government has certain rights in the invention.FIELD OF THE INVENTION[0003]The present invention relates generally to extrusion processing and extrusion tools. More particularly, the invention relates to a shear-assisted extrusion system and process for production of extrusion structures including high-performance extrusion structures.BACKGROUND OF THE INVENTION[0004]Extrusion is a process in which a billet or block of material composed of metals, polymers, ceramics, or foodstuffs is forced through an extrusion die with a ram tool that...

AI Technical Summary

Benefits of technology

[0020]In some applications, extrusion structures are tubular extrusion structures that may be included as components of a compression device, a stent device, a bending-resistant device. Compression devices include, but are not limited to, e.g., compression bumpers or collapsible safety frames deployed in automobiles. In various applications, extrusion structures of the present invention may be incorporated as components of selected structures such as in support pillars or other structures deployed in vehicles to enhance mechanical properties, performance, or to resist bending. In some applications, extrusion structures may be included as components of a stent device.

Problems solved by technology

In addition, non-uniform deformation of extrudates is common, which yields extrusion products with structural and physical property variations in both the longitudinal and transverse directions.

Further, microstructure refinement is often inconsistent and typically insufficient so mechanical properties vary widely.

And, while processes like mechanical alloying, rapid solidification, friction stir processing, equal channel angular extrusion, twist extrusion, waffle pattern rolling, non-axis symmetric rolling, and other processes have been used to make high performance materials, such processes are not presently cost-effective for commercial production.

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