Shear-assisted extrusion apparatus, tool and method

Abstract

Shear-assisted extrusion devices, tools, inserts, and / or methods are provided. In some embodiments, an apparatus may include: an extrusion receiving channel operably engaged with a tool to receive an extrusion material; and one or more openings aligned between the spindle ends, the openings configured to deliver a fluid to the extruded product. An example tool may include one or more openings aligned between the tool ends. An example method may include quenching the plasticized feed material before the plasticized feed material leaves the spindle. There is also provided a spindle assembly insert and / or a tool assembly insert that may include a sleeve extending within one or both of a spindle assembly or a tool assembly of the apparatus; and an opening in the sleeve configured to deliver fluid into one or both of the receiving channel of the spindle assembly or the receiving channel of the tool assembly.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority to U.S. Patent Application Serial No. 17 / 857,951, filed on July 5, 2022, which is related to U.S. Continuation-in-Part Patent Application Serial No. 17 / 473,178, entitled “Devices and Methods for Performing Shear-Assisted Extrusion and Extrusion Processes,” filed on September 13, 2021. The entire contents of each of the above applications are hereby incorporated herein by reference.

[0003] STATEMENT AS TO RIGHTS TO INVENTIONS MADE UNDER FEDERALLY SPONSORED RESEARCH AND DEVELOPMENT

[0004] This invention was made with government support under Contract DE-AC05-76RL01830 awarded by the U.S. Department of Energy. The government has certain rights in this invention. Technical Field

[0005] The present disclosure relates generally to metal technology, but more particularly to extrusion technology. Background Art

[0006] The increase in demand for fuel efficiency in transportation combined with the increasing demand for safety and regulatory compliance has focused attention on the development and utilization of new materials and processes. In many cases, the barrier to entry into these areas is caused by the lack of effective and efficient manufacturing methods. For example, the ability to replace steel automotive parts with materials made of magnesium or aluminum or their associated alloys is very important. In addition, the ability to form hollow parts with the same or greater strength than solid parts is an additional desired goal. Previous attempts have failed or been limited based on a variety of factors, including the lack of a suitable manufacturing process, the cost of using rare earths in alloys to impart desired properties, and the high energy costs for production.

[0007] What is needed is such a process and apparatus that enables the production of articles with hollow cross-sections, such as parts in automobiles or aerospace vehicles, which are made of materials such as magnesium or aluminum with or without rare earth metals. Also needed is a process and system for producing such articles, which is more energy-efficient, can be implemented more simply, and will produce materials with desired grain size, structure and alignment to maintain strength and provide sufficient corrosion resistance. Also needed is a simplified process that can form such structures directly from billets, powders or material sheets without the need for additional processing steps. Also needed is a process and associated equipment that reduces or eliminates the need for energy-intensive heat treatment steps before and / or after extrusion. Also needed is a new method for forming high entropy alloy materials that is simpler and more efficient than current processes. The present disclosure provides a description of significant progress in meeting these needs.

[0008] 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 punch or die to receive an axially fed billet, rather than receiving an axially fed billet without rotation as used in conventional extrusion processes. As described below and in previously cited, referenced, and incorporated patent applications, the process and its associated apparatus provide a number of significant advantages, including reduced power consumption, less and less demanding heat treatments, better material properties, and a new collection of "solid phase" type forming processes and machines. It is envisioned that the advantages of these processes and apparatus will be utilized in a variety of industries and applications, including but not limited to transportation, missiles, high temperature applications, structural applications, nuclear applications, and corrosion resistance applications.

[0009] The present disclosure overcomes many of the requirements of the prior art by eliminating steps entirely and providing extruded materials of higher quality than those produced by these prior art methods. Summary of the invention

[0010] A shear-assisted extrusion apparatus is provided. The apparatus may include: a spindle assembly extending from a first end to a second end, the spindle assembly being configured to rotate about a distance between the first end and the second end; a tool operably engaged with the spindle and defining the second end of the spindle assembly, the tool being configured to engage a feed material using a shear force provided from the spindle; an extrusion receiving channel operably engaged with the tool to receive an extrusion material; and one or more openings aligned between the first end and the second end, the openings being configured to deliver a fluid to an extruded product.

[0011] Shear-assisted extrusion tools are also provided. These tools may include: 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, the second end configured to be operably coupled to a spindle of a shear-assisted extrusion device; and one or more openings aligned between the first end and the second end, the openings configured to deliver a fluid through an inner wall of the conduit and / or the die face.

[0012] A method for quenching a product of shear-assisted extrusion is also provided. The method may include: providing a shear-assist force to a die face operatively engaged with a spindle of a shear-assisted extrusion apparatus; and receiving plasticized raw material from the die face and quenching the plasticized feed material before the plasticized feed material exits the spindle.

[0013] A spindle assembly insert and / or a tool assembly insert is provided, comprising: a sleeve extending within one or both of a spindle assembly or a tool assembly of an apparatus; and openings within the sleeve configured to deliver a fluid into one or both of a receiving channel of the spindle assembly or a receiving channel of the tool assembly.

[0014] The devices, tools, inserts, and / or methods disclosed herein are example configurations and are not exhaustive descriptions of all configurations contemplated. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] Embodiments of the present disclosure are described below with reference to the following drawings.

[0016] Figure 1 It is part of a shear-assisted extrusion device according to an embodiment of the present disclosure.

[0017] Figure 2 is another configuration of a portion of a shear-assisted extrusion apparatus according to an embodiment of the present disclosure.

[0018] Figure 3 is a more detailed view of a portion of a shear assisted extrusion apparatus according to an embodiment of the present disclosure.

[0019] Figure 4 is a depiction of a portion of a shear-assisted extrusion apparatus according to an embodiment of the present disclosure.

[0020] Figure 5 A shear-assisted extrusion device according to an embodiment of the present disclosure.

[0021] Figure 6 is a more detailed view of a portion of a shear assisted extrusion apparatus according to an embodiment of the present disclosure.

[0022] Figure 7is an external view of components of a shear-assisted extrusion apparatus according to an embodiment of the present disclosure.

[0023] Figure 8 is a detailed view of a portion of a shear-assisted extrusion apparatus according to an embodiment of the present disclosure.

[0024] Fig. 9 is a detailed view of a shear-assisted extrusion apparatus according to an embodiment of the present disclosure.

[0025] Fig.10 is an illustration of components of a shear-assisted extrusion apparatus having a quench insert therein according to an embodiment of the present disclosure.

[0026] Fig.11 is a detailed view of a portion of the engagement of a quench insert with components of a shear-assisted extrusion apparatus according to an embodiment of the present disclosure.

[0027] Fig.12 is a detailed view of a portion of the engagement of a quench insert with components of a shear-assisted extrusion apparatus according to an embodiment of the present disclosure.

[0028] Fig.13 According to the embodiments of the present disclosure Fig.12 Detailed view of the components.

[0029] Fig.14 According to the embodiments of the present disclosure Fig.13 Detailed view of the components.

[0030] Fig.15 According to the embodiments of the present disclosure Fig.14 Detailed view of the components.

[0031] Fig.16 and Fig.17 are depictions of different quench head configurations according to embodiments of the present disclosure.

[0032] Fig.18 is a depiction of a quench assembly within a shear assisted extrusion apparatus according to an embodiment of the present disclosure.

[0033] Fig.19 and Fig. 20 is a depiction of an exhaust assembly according to an embodiment of the present disclosure. DETAILED DESCRIPTION

[0034] Will refer to Figures 1 to 20 The apparatus, tools and methods of the present disclosure are described. Figure 1, a portion 10 of a shear-assisted extrusion apparatus is shown, the shear-assisted extrusion apparatus 10 including a feed material 20 located within a feed material container 24 and a shear-assisted extrusion tool 16, the shear-assisted extrusion tool 16 including a tool head 12 and a die face 14 extending to a shank 15. The shank 15 can be defined by a tube having an interior 19 and an exterior sidewall 17. The tool 16 also includes a flange 18 that can 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 can be assemblies of multiple components. An example tool assembly is depicted herein. As shown, a rotational force and an axial force are applied to the tool head 12. The axial force can be applied from the tool to the feed material; alternatively, the axial force can be applied from the feed material to the tool. According to an example implementation, the shear-assisted extrusion process will provide an extruded material 22.

[0035] Next, refer to Figure 2 , shows a portion of the apparatus 10 that includes the use of a mandrel 26 that is configured to provide a feed material 20 to the die face 14 and / or into the tool 16. The mandrel 26 can extend to the die face 14 where the feed material is plasticized and the plasticized material continues to travel as extruded material within the tool 16 to form an extruded material 22. Alternatively, the mandrel 26 can continue to extend beyond the die face 14 and provide support for the extruded material within the tool 16 after the extruded material is formed at the die face 14. According to an example implementation, the material 22 can take the shape of the mandrel 26. Extruded materials including non-circular multi-cell profiles can also be formed using a port hole bridge tool / die configuration as an alternative to the depicted mandrel approach.

[0036] Next, refer to Figure 3 , provides Figure 2 , which includes a mandrel 26 that supports a feed material, also referred to as a billet 20, within a container 24. As shown, the tool 16 may include a die face 14 and a tool head 12, and is configured to form an extruded material 22 under the action of rotational and axial forces as shown.

[0037] Next, refer to Figure 4, according to an example implementation, a device portion 40 is shown that includes both a tool 16 and a spindle 42 that rotates about a receiving channel 44. Importantly, the receiving channel 44 is stationary or fixed relative to the spindle 42. The spindle 42 is operable to rotate the tool 16 so as to provide the rotational force mentioned herein, and the spindle extends from one end 92 and another end 90, where the spindle is coupled to the tool 16 at, for example, a flange 18, and the spindle is coupled to the rest of the device and ends the rotation to allow the receiving channel 44 to continue to extend as shown. Therefore, the joints 90 and 92 are shown to allow the spindle 42 to rotate while the channel 44 remains fixed. Alternatively, at the joint 92 between the flange 18 and the spindle 42, the components are fixed, thereby providing rotation of the tool 16 according to the rotation of the spindle 42.

[0038] According to the example implementation and reference Figure 4 , a passage 60 is provided in the receiving passage 44, and the tool 16 is provided with a passage 50. As shown, openings 52 can enter the inner wall of the tool 16 from these passages, and openings 62 can enter the inner wall of the receiving passage from these passages. Fluids, such as coolants, can be provided to these passages. Examples of coolants can include, but are not limited to, water, air, inert gas, liquid nitrogen, nitrogen mist, and / or quenching oil.

[0039] Next, refer to Figure 5 , the various parts of the apparatus provided herein can be operatively joined using the complete apparatus as shown. This example apparatus is referred to as a "friction extruder" or "shear-assisted processing and extruder," examples and operations of which are further provided in U.S. Patent Application No. 17 / 473,178 filed on September 13, 2021, which was published as Publication No. US2021 / 0402471 A1 on December 30, 2021, the entire contents of which are incorporated herein by reference.

[0040] Next, refer to Figure 6 According to one particular embodiment, the apparatus portion 110 may include a mandrel 26 that supports a feed material 20. The feed material 20 may engage the die face 14 at the tool head 12 and be plasticized to form the extruded material 22. According to an example implementation, the fluid may be provided at the passage 70 or 72 through the spindle 42, which may include a spindle face plate, via the spindle exterior and / or via the flange 18 of the tool assembly 16. As depicted herein, the tool assembly 16 may include a tool or die holder 66 and a die 68. According to an example implementation, the passage 50 may continue to extend and the fluid may be provided into the inner wall of the tool 16 through the opening 52. Figure 7An external view of the spindle 42 is depicted coupled to the tool assembly 16 and the mandrel 26. As shown, passages 70 / 50 and / or 72 / 50 provide fluid to the tool assembly 16.

[0041] Next, refer to Figure 8 , another example implementation of an apparatus portion 120 of a shear-assisted extrusion apparatus is shown, the apparatus portion 120 comprising a tool assembly 16 having a tool holder 66 operatively coupled to a tool / die 68. The tool / die 68 comprises a die face 14 and a tool head 12. According to an example implementation, a passage 50 may extend through the holder 66 and through the wall of the tool / die 68, and then be in fluid communication with an opening 52 that enters into a rear face or a bearing face of the die face 14. At the head 12, a plasticized material is formed and flows to be cooled or quenched. As depicted, the assembly 16 may include a coupler 122 that may be used to couple the tool / die 68 to the holder 66.

[0042] Next, refer to Fig. 9 According to yet another implementation, an apparatus portion 130 of a shear-assisted extrusion apparatus is shown, the apparatus portion 130 including the feed material 20 engaged with the die face 14 at the tool head 12. According to an example implementation, the conduit 50 may extend through the tool 68 and exit at the opening 52 located on the support or rear face 90 of the die face 14.

[0043] Next, refer to Fig.10 , as shown, an assembly 200 is shown, which includes a tool assembly 16 operatively coupled to a spindle assembly 42, and the spindle assembly 42 includes a spindle faceplate 100 coupled to a spindle 102. The spindle 102 is operatively engaged with a rotary joint 104. Within the assembly 200 is a quench assembly 106. The quench assembly 106 can be a part of these components and / or an insert of already assembled components. The spindle assembly 42 can include components that rotate axially about the distance between the ends of the spindle assembly, such as about the distance between the tool assembly 16 and the rotary joint 104, between the faceplate 100 and the rotary joint 104, and / or about the length of the spindle 102.

[0044] Next, refer to Fig.11 According to an example implementation, fluid may be provided into passage 60 formed between receiving passage 44 and sleeve 144 via inlet 66 to reach opening 62 in sleeve 144. As shown, sleeve 144 extends into swivel 104 and continues through main shaft 42.

[0045] Next, refer to Figure 12 to Figure 14 And referring to the previous Fig.10, depicts a quench assembly 106 that can extend into the spindle 42 to the tool assembly 16. In particular embodiments, the assembly 106 can include a quench head 162. The quench head 162 can include a plurality of openings 62 in fluid communication with a passage 60 disposed between the sleeve 144 and the receiving channel 44. According to an example implementation, the quench head 162 can be aligned within the spindle faceplate 100 proximate to the tool assembly 16, which can be configured to receive an extruded material 22. The sleeve 168 can be operatively engaged with the tool assembly 16 and can extend from the tool holder 66 or the quench head 162 to the support portion 90 to form a passage 50 between the assembly 16 and the extruded material 22. Thus, fluid can be provided to the passage 60 and the passage 50 and exit the tool assembly 16 at the openings 52. As shown in FIG. Fig.14 As shown, waste or spent fluid 54 is shown returning along with the extruded material 22 .

[0046] like Fig.15 As shown in FIG. 1 , the fluid 54 continues along the extrusion direction 150 with the extruded material 22. Therefore, the fluid from the opening 62 can further promote the flow of the fluid 54. Fig.16 and Fig.17 As shown in the figure, the openings 62 can be configured to direct the fluid flow around the extruded material without directing the fluid flow to each other. Therefore, the fluid flow can be offset to form radial joints 180 of various sizes. As shown in the figure, Fig.16 The radius ratio of the radial joint Fig.17 The radius of the radial joint shown in is small.

[0047] According to another example, Fig.18 As shown in FIG. 1 , fluid may be provided via mandrel 26 to a quench head 162 having opening 74 to quench the interior of extruded material 22. Spent or used fluid 54 may continue to travel in the extrusion direction.

[0048] Next, refer to Fig.19 and Fig. 20 , the fluid 54 can be retrieved at the opening 190 for reuse. Fig. 20 As shown in , the opening 190 can be part of the reservoir assembly to prevent the fluid 54 from continuing to travel with the extruded material. This exhaust can be recovered and then re-cooled and returned for future use.

Claims

1. A shear-assisted extrusion device, comprising: a spindle assembly extending from a first end to a second end, the spindle assembly being configured to rotate about a distance between the first end and the second end; a tool or blank operatively engaged with the spindle and defining the second end of the spindle assembly, the tool being configured to engage a feed material utilizing shear forces provided from the spindle; an extrusion receiving channel operably engaged with the tool to receive extrusion material; as well as One or more openings are aligned between the first end and the second end, the openings configured to deliver a fluid to the extruded product.

2. The device according to 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 passage.

4. The device according to claim 1, wherein: At least one of the openings is within the tool.

5. The device according to claim 4, wherein: At least one of the openings located within the tool extends through an inner wall of the tool.

6. The device according to claim 5, wherein: The inner wall of the tool supports a mold 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 passage and the spindle, the space configured to provide fluid to one or more of the openings.

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

10. The apparatus of claim 1, further comprising at least one fluid outlet opening located within the receiving passage.

11. A shear-assisted extrusion tool, the tool comprising: a conduit extending from a first end defining a die face and configured to engage a feed material to a second end configured to be operably coupled to a spindle of a shear-assisted extrusion apparatus; as well as One or more openings are aligned between the first end and the second end, the openings configured to deliver fluid through the inner wall of the conduit and / or the mold face.

12. The tool according to claim 11, wherein: The tool defines a handle between the first end and the second end, the tool further comprising a passage extending through the handle and in fluid communication with one or more of the openings.

13. The tool according to claim 12, wherein: The passageway extends between a first end and a second end of the handle.

14. The tool according to claim 12, wherein: One or more of the openings extend through an inner wall defined by the handle.

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

16. The tool of claim 15, further comprising a passageway within the conduit and in fluid communication with one or more of the openings extending through the interior portion of the mold face.

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

18. The tool according to claim 17, wherein: The passageway is configured to be operatively coupled to a fluid inlet.

19. The tool according to claim 18, wherein: The passageway is configured to be operably coupled to a spindle of a shear-assisted extrusion tool.

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

21. A method for quenching a product of shear assisted extrusion, the method comprising: providing a shear-assist force to a die face operatively engaged with a spindle of a shear-assist extrusion apparatus; as well as Plasticized raw material is received from the die face and the plasticized feed material is quenched before the plasticized feed material exits the spindle.

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

23. The method according to claim 22, wherein: The fluid is provided to the plasticized feed material after the plasticized feed material passes through the die face.

24. The method according to claim 21, wherein: The fluid is provided by a tool supporting the mold surface.

25. The method according to claim 21, wherein: The fluid is provided via a mandrel operatively coupled to the mold face.

26. The method of claim 22, further comprising providing a fluid to a receiving passage in the main shaft.

27. The method according to claim 26, wherein: The receiving channel operably engages a tool of the mold face, and the method further includes providing a fluid to an end of the receiving channel operably engaged with the tool.

28. The method according to claim 26, wherein: The receiving passage operably engages an outlet of the spindle, and the method further includes providing a fluid to an end of the receiving passage operably engaged with the outlet of the spindle.

29. The method of claim 22, further comprising discharging fluid through the receiving passage.

30. The method of claim 29, wherein: The exhaust is external to the spindle.

31. A quench insert for a shear assisted extrusion apparatus, the insert comprising: a sleeve extending within one or both of a spindle assembly or a tool assembly of the apparatus; as well as An opening in the sleeve is configured to deliver fluid to one or both of the receiving passage of the spindle assembly or the receiving passage of the tool assembly.

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

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

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

35. The insert of claim 31 further comprising an outlet operatively engaged with the sleeve.

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

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