Direct shear-assisted extrusion machine

Abstract

A system for performing shear-assisted extrusion can include a die tool, a headstock, a midstock, and a tailstock. The die tool can include a face configured to engage and plasticize a portion of feedstock material engaged with the face. The die tool can define an opening to receive plasticized feedstock material therethrough. The headstock can be secured to the die tool. The headstock and the die tool can be together rotatable about a central axis to generate a rotation-induced shear force between feedstock material and the die tool to extrude the feedstock material through the opening of the die tool. The midstock can be configured to support the feedstock material at least partially therein. The tailstock can be configured to translate along the central axis relative to the headstock and the headstock to generate an axial extrusion force between the feedstock material and the die tool.

Description

DIRECT SHEAR-ASSISTED EXTRUSION MACHINECLAIM OF PRIORITY

[0001] This patent application claims the benefit of priority, under 35 U.S.C.Section 119(e), to Scott Whalen U.S. Patent Application Serial Number 63 / 753,046, entitled “SHEAR- ASSISTED EXTRUSION LINER,” filed on February 3, 2025 and to Brandon Scott Taysom U.S. Patent Application Serial Number 63 / 702,547, entitled “DIRECT SHEAR- ASSISTED EXTRUSION MACHINE,” filed on October 2, 2024, which are hereby incorporated by reference herein in their entirety.STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

[0002] This invention was made with Government support under Contract DE- AC0576RL01830 awarded by the U.S. Department of Energy. The Government has certain rights in the invention.BACKGROUND

[0003] Extrusion is a machining process where raw material, such as a billet, can be forced or extruded through one or more openings to form extrudate. Metals, ceramics, polymers, and the like can be extruded into various shapes for various uses. 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 process is commonly used to form pipes, tubes, and the like.BRIEF DESCRIPTION OF THE DRAWINGS

[0004] 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.

[0005] FIGS. 1 A illustrates a portion of an extrusion system.

[0006] FIGS. IB illustrates a portion of an extrusion system.

[0007] FIG. 2A illustrates a portion of an extrusion system.

[0008] FIG. 2B illustrates a portion of an extrusion system.

[0009] FIG. 3 A illustrates a top isometric view of a porthole die.

[0010] FIG. 3B illustrates a bottom isometric view of a porthole die.

[0011] FIG. 4 illustrates a top schematic view of a shear-assisted extrusion system.

[0012] FIG. 5 illustrates a cross-sectional schematic view of a shear-assisted extrusion system.

[0013] FIG. 6 illustrates a cross-sectional isometric view of a portion of a shear- assisted extrusion system.

[0014] FIG. 7 illustrates a cross-sectional isometric view of a portion of a shear- assisted extrusion system.

[0015] FIG. 8 illustrates a cross-sectional side view of a portion of a shear-assisted extrusion system.

[0016] FIG. 9 illustrates a cross-sectional schematic view of a shear-assisted extrusion system.

[0017] FIG. 10 illustrates a cross-sectional isometric view of a portion of a shear- assisted extrusion system.

[0018] FIG. 11 illustrates a cross-sectional side view of a portion of a shear- assisted extrusion system.

[0019] FIG. 12 illustrates a cross-sectional side view of a portion of a shear- assisted extrusion system.

[0020] FIG. 13 illustrates a cross-sectional side view of a portion of a of a shear- assisted extrusion system.

[0021] FIG. 14 illustrates a cross-sectional isometric view of a portion of a shear- assisted extrusion system.

[0022] FIG. 15A illustrates a cross-sectional side view of a portion of a shear- assisted extrusion system.

[0023] FIG. 15B illustrates a cross-sectional side view of a portion of a shear- assisted extrusion system.

[0024] FIG. 15C illustrates a cross-sectional side view of a portion of a shear- assisted extrusion system.

[0025] FIG. 16 illustrates a schematic view of a method of operating one or more systems.

[0026] FIG. 17 illustrates an isometric cross-sectional view of a portion of an extrusion machine.

[0027] FIG. 18 illustrates an isometric view of a portion of an extrusion machine.

[0028] FIG. 19 illustrates an isometric view of a portion of an extrusion machine.

[0029] FIG. 20 illustrates an isometric view of a portion of an extrusion machine.

[0030] FIG. 21 illustrates an isometric view of a portion of an extrusion machine.

[0031] FIG. 22 illustrates an isometric view of a portion of an extrusion machine.

[0032] FIG. 23 illustrates an isometric view of a portion of an extrusion machine.

[0033] FIG. 24 illustrates an isometric view of a portion of an extrusion machine.

[0034] FIG. 25 illustrates an isometric view of a portion of an extrusion machine.

[0035] FIG. 26 illustrates an isometric view of a portion of an extrusion machine.

[0036] FIG. 27 illustrates an isometric cross-sectional schematic view of an extrusion machine.

[0037] FIG. 28 illustrates an isometric cross-sectional view of a portion of an extrusion machine.

[0038] FIG. 29 illustrates an isometric cross-sectional view of a portion of an extrusion machine.

[0039] FIG. 30 illustrates an isometric exploded view a portion of an extrusion machine.

[0040] FIG. 31 illustrates an isometric cross-sectional view of a portion of an extrusion machine.

[0041] FIG. 32 illustrates an isometric cross-sectional view of a portion of an extrusion machine.

[0042] FIG. 33 illustrates an isometric cross-sectional view of a portion of an extrusion machine.

[0043] FIG. 34 illustrates an isometric view of a portion of an extrusion machine.

[0044] FIG. 35 illustrates an isometric view of a portion of an extrusion machine.

[0045] FIG. 36 illustrates an isometric cross-sectional view of an extrusion machine.

[0046] FIG. 37 illustrates an isometric cross-sectional view of a portion of an extrusion machine.

[0047] FIG. 38 illustrates a block diagram illustrating an example of a machine upon which one or more embodiments may be implemented.DETAILED DESCRIPTION

[0048] In the field of extrusion, there is a need to produce extrudate having complex shapes at a reduce energy usage. Shear assisted extrusion processes (ShAPE) have been used to generate extrudate at a reduced energy usage; however, to date, most of the processes use indirect extrusion, which can may be less scalable.

[0049] The present techniques can help address one or more of the challenges mentioned above, such as by using direct extrusion with a machine that includes multiple moving stocks and spindles, which can be. For example, the machine can include a headstock with a rotating die tool and can include a tailstock that can generate an axial extrusion force. Such a machine can also include a movable midstock, which can be used for machine service and loading of feedstock. This type of direct extrusion ShAPE machine can be relatively more scalable for manufacturing purposes.

[0050] In another example, a machine can include a fixed endstock supporting a non-rotating die tool. The machine can also include a translating tailstock configured to generate the axial extrusion force(s) and a translating midstock that can also generate the axial moving force(s). The tailstock and the midstock can each include rotating spindles to allow the machine to generate torque or rotational forces to generate rotation induced shear between the die tool and the billet or feedstock. This type of direct extrusion ShAPE machine can be relatively more scalable for manufacturing purposes and can produce non-rotating extrudate, which may be preferable for manufacturing at scale.

[0051] Also, in the field of energy conversion and energy transport, there is a need to develop materials (e.g., alloys, composites, etc.) with improved material characteristics, while being able to make complex shapes using lower input energy. The present techniques can help address one or more of the challenges mentioned above, such as using shear assisted processing and extrusion (ShAPE) or friction stir extrusion (FSE or FE) to produce 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. These extrusion processes 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 overallenergy consumption and processing time for extrusion. However, performing ShAPE or friction stir extrusion can be relatively difficult due to the requisite axial and rotational forces required to extrude metallic components. For example, a feedstock container can be subject to relatively high forces during extrusion that can damage the container. For this reason, a replaceable liner can be used to protect the container. However, due to the use of rotation during ShAPE or friction stir extrusion, the liner is generally inhibited from rotation relative to the container.

[0052] The present disclosure discusses various examples of a liner that can be fixed to a container and can be prevented from rotating relative to the container. For example, the liner can be configured to rotate with the container (and not relative to the container) as a unitized assembly for extrusion processes while still being replaceable or removable from the container. The liner can include keyed features configured to receive rotational input from a driving component, such as a spindle so that the liner rotates together with the container during ShAPE or friction stir extrusion. Alternatively, or in addition, such keyed features can be used to positively engage the liner to fix the liner in a specified rotational position or alignment relative to other portions of the system such as the container. Such a liner can be used in either direct or indirect extrusion systems or processes.

[0053] 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.

[0054] FIG. 1 A illustrates a system 100 for extruding a structure having a hollow cross section using a shear-assisted direct extrusion technique. The system 100 can be configured to use one or more shear-assisted process involving applying an axial compression force and a rotation-induced shear force. Though shear-assisted machines and processes are discussed below, the system 100 can also be used to perform other types of processes such as Friction Stir Extrusion or Friction Extrusion.

[0055] As shown in FIG. 1 A, 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 can even be flat. The billet material 120 can be held within abillet holder assembly 112 that can include a container base 112A and a container sidewall 112B.

[0056] A die shank 114 can be retained within die holder 121 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) and the axial movement (illustrated by the double-sided arrow T) of the die face 128 can induce shear to plasticize the billet material 120 at the interface between the die face 128 and the billet material 120. The plasticized material can flow in a specified direction.

[0057] As shown in FIG. IB, the system 100 can also be configured such that the billet holder assembly 112 and the billet material 120 can spin or rotate 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) relative to the other, the combination of the axial and the rotating forces can plasticize the billet material 120 at the interface with the die face 128.

[0058] 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”) A can be defined to extend through a center of the die face orifice 38. The die assembly 110 can rotate about the central longitudinal axis A 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 38 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.

[0059] The mandrel 116 can be in close proximity to the die face 128 (or 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 ease of illustration) that the plasticized extrusion material is extruded through to form theextruded 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 between two portions of the die face 128 is illustrated in FIG. 2.

[0060] FIG. IB illustrates, by way of example and not limitation, a system 100 for extruding a structure having a hollow cross section. FIG. IB, 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. IB illustrates an example of a die assembly 110 that moves or translates axially along the longitudinal axis A and a container sidewall 112B and container base 112A that can rotate about the longitudinal axis A. 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. 1 A 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.

[0061] While the illustrations of FIG. 1A and FIG. IB 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 or the die may have slight or lesser rotational movement.

[0062] FIG. 2A illustrates a cross-sectional view of an extrusion system 100. FIG. 2B illustrates a cross-sectional view of an extrusion system 100. FIGS. 2A and 2B are discussed together below.

[0063] As shown in FIGS. 2A and 2B, 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 rotatesrelative 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.

[0064] 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 between the die face 128 and the billet material 120. Rotation and the axial movement of the components can induce shear to plasticize the billet material 120 at or adjacent to the interface between the die face 128 and the billet material 120. The plasticized material can flow in a specified direction. In FIGS. 2A and 2, a ram can be used to press just the billet against the die face, as in direct extrusion, rather than translating the entire container, liner, and billet assembly to engage the billet with the die face.

[0065] Flow of the plasticized material can 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”) A can be defined to extend through a center of the die 110. The mandrel 116 can be a part of the billet holder assembly 112 in the case of drawn-over-mandrel configurations, or 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 ease of illustration) that the plasticized extrusion material is extruded through to form the extruded structure. The extrusion aperture can be formed when the mandrel 116 is extended through a die face orifice 138 in the die face 128. In some examples, the mandrel 116 can be rigidly affixed to the die face 128 is illustrated in FIG. 2B.

[0066] The extrusion system 100 of FIGS. 2A and 2B can be similarly configured but can move differently. For example, as shown in FIG. 2A, the die assembly 110 (including the die holder 121, the die shank 114, and the porthole die 122) can be configured to rotate relative to or about the axis A relative to the billet holder assembly 112 to generate a rotational force that helps to create a rotation-inducedshear force between the die face 128 and the billet material 120. Meanwhile, the billet holder assembly 112 (including the container base 112 A, the container sidewall 112B, the liner 132, and the billet material 120) can be configured to translate along the axis A relative to the die assembly 110 to generate an axial force that helps to create the rotation-induced shear force between the die face 128 and the billet material 120.

[0067] As shown in FIG. 2B, the billet holder assembly 112 (including the container base 112A, the container sidewall 112B, the liner 132, and the billet material 120) can be configured to rotate relative to or about the axis A relative to the die assembly 110 to generate a rotational force that helps to create a rotation-induced shear force between the die face 128 and the billet material 120. Meanwhile, die assembly 110 (including the die holder 121, the die shank 114, and the porthole die 122) can be configured to translate along the axis A relative to the billet holder assembly 112 to generate an axial force that helps to create the rotation-induced shear force between the die face 128 and the billet material 120.

[0068] 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. Whichever way rotational movement and translation occurs, the die face 128 and billet material 120 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. The extruded structure can be extruded through an internal portion 111 of the die shank 114. Reconstitution of plasticized material can occur defining a hollow-interior extruded structure (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 can be optional, and specified microstructure or other physical characteristics can be established using shear-assisted processing alone. The discussion of FIGS. 1-2 above can also apply to a configuration that includes a mandrel piercing through the billet and a non-porthole die to create seamless tubing.

[0069] FIGS. 3 A and 3B illustrate respective top and bottom isometric views of a porthole die with a modified scroll face and mandrel. FIG. 3 A 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.

[0070] 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.

[0071] In this 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.

[0072] 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 toenable 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. 1 A-1B, the porthole die configuration in FIGS. 3A-3B, or additional configurations not illustrated, the variation of rotational or axial movements described herein can be used with any number of die face configurations or associated mandrels.

[0073] FIG. 4 illustrates a top schematic view of a shear-assisted extrusion system 400. The shear-assisted extrusion system 400 can include a ShAPE machine 402 that can be similar to the system 100 discussed above or can be or include any of the ShAPE machines discussed below. The shear-assisted extrusion system 400 can also include a control cabinet 404 that can be connected to or separately located from the ShAPE machine 402 or a housing thereof. The control cabinet 404 can be configured to at least partially support or enclosed one or more control devices for operating the shear-assisted extrusion system 400, such as one or more controllers or the like.

[0074] The control cabinet 404 can be configured to include or support a controller 405 at least partially therein. The controller 405 can be connected or connectable to one or more components of the system 100 (or the system 500 discussed below). For example, the controller 405 can be in communication with one or more sensors, motors (e.g., spindle motors or actuators) or the like. The controller 405 can be a programable controller, such as a single or multi-board computer, a direct digital controller (DDC), a programable logic controller (PLC), printed circuit board (PCB), or the like. In other examples the controller 405 can be any computing device, such as a handheld computer, for example, a smart phone, a tablet, a laptop, a desktop computer, or any other computing device including a processor, memory, and communication capabilities.

[0075] The shear-assisted extrusion system 400 can be configured or operable to perform one or more ShAPE operations such as direct or indirect ShAPE extrusion to generate extrudate 406 using various stocks, spindles, and die tools as discussed in further detail below.

[0076] FIG. 5 illustrates a cross-sectional schematic view of a portion of a ShAPE machine 502. The ShAPE machine 502 can be (or can be similar to) the ShAPE machine 402 discussed above or any of the other ShAPE machines discussed above or below, such that the features of the machine 502 can be included in any of the ShAPE machines discussed above or below.

[0077] The machine 502 can include a headstock 540, a midstock 542, and a tailstock 544. The headstock 540, the midstock 542, and the tailstock 544 can be rigid or semi-rigid components configured to process feedstock or a billet 546. The headstock 540, the midstock 542, and the tailstock 544 can be configured to react to linear and torsional forces of the machine 502, which may or may not be identical. Though the headstock 540, the midstock 542, and the tailstock 544 are referred to as “head” and “mid” and “tail” these terms are used merely to indicate relative positions of the recited elements with respect to each other, and not some other absolute frame of reference. The component orientation names can be reversed, or can be replaced by “first” and “second” or the like.

[0078] The machine 502 can also include one or more tooling plates. For example, the headstock 540 can include a tooling plate 548 that can be secured to a rear portion of the headstock 540. The machine 502 can also include a tooling plate 550 secured to a front portion of the midstock 542 and the machine 502 can include a tooling plate 552 secured to a front portion of the tailstock 544. The tooling plate 548 can be rotatable with a spindle of the headstock 540. The machine 502 can also include a die tool 554 including a die face 556 located at a rear portion of the die tool 554, and the die tool 554 can include an opening 558 that can extend along the central axis A through the die tool 554. During extrusion operations, the die face 556 can be configured to engage and plasticize portions of the billet 546 engaged with the die face 556 and the opening 558 can receive plasticized material therethrough.

[0079] The machine 502 can also include a container 560 located at (or connected to or adjacent to) a radially inner surface of the headstock 540, such as the tooling plate 550. The container 560 can be connected to or included in the midstock 542 and movable therewith. The container 560 can be configured to support the billet 546 at least partially therein. The machine 502 can also include a liner 562 that can include a bore 564, where the bore 564 can extend along the central axis A. The liner 562 can be located at (or connected to or adjacent to) a radially inner surface of the container 560. The liner 562 can be configured to engage and support the billet 546 within the bore 564 of the liner 562. The liner 562 can be releasably securable or secured to the container 560 such that the liner 562 is relatively easily replaceable. Because the billet 546 and the ram can engage the liner 562 during extrusion operations, the liner 562 can become damaged. Because the liner 562 can be easily replaced, damage of the machine 502 can be limited and maintenance or repair can be relatively low cost. Insome examples, the liner 562 can be excluded and the container 560 can receive the feedstock or the billet 546 directly. In such an example, the container 560 can be relatively easily replaced.

[0080] FIG. 5 also shows that the machine 502 can include a ram 566 secured to the tooling plate 552. The ram 566 can be translatable with the tailstock 544 such as along the central axis A as indicated by the arrow indicators T1 relative to the headstock 540 and the midstock 542. The ram 566 can be configured to extend at least partially into the bore 564 of the liner 562, allowing the ram 566 to engage the billet 546. The midstock 542 (along with the container 560, the liner 562, and the billet 546) can also be translatable along the central axis A as indicated by the arrow indicators T2 relative to the headstock 540 and the tailstock 544. Also, the headstock 540 can include one or more spindle and motor configured to rotate the headstock 540 including the tooling plate 548 and the die tool 554 about the central axis A, as indicated by the arrow R1.

[0081] In operation of some examples, feedstock material (e.g., the billet 546) can be loaded into the bore 564 of the liner 562 and the die tool die tool 554 can be secured to the tooling plate 548. When the feedstock material is loaded, an extrusion process can begin where one or more spindles connected to the headstock 540 can be rotated to rotate the tooling plate 548 and the die tool 554 to establish a rotation- induced shear force at an interface between the die tool and the feedstock material. Also, the tailstock 544 can be translated (e.g., along the central axis A) to translate the ram 566 into the bore 564 to engage the billet 546 to establish an axial extrusion force. During extrusion, the rotating die face 556 can engage the billet 546 resulting in shear-assisted extrusion and generating plasticized material that can enter the opening 558. Reconstitution of plasticized material can occur downstream of the die face 556 (as discussed above) to generate extrudate which can include one or more desired characteristics.

[0082] Though the midstock 542 is shown and discussed as being translatable, the midstock 542 is not required to translate during extrusion, as the rotational forces can be generated by the headstock 540 and the axial forces can be generated by the tailstock 544. However, the midstock 542 can be translatable (manually or automatically) before or after a process such as for maintenance of the machine 502 or for loading or unloading of material, such as loading of the billet 546 into the bore 564 prior to the extrusion process. The machine 502 can therefore provide the abilityto service and operate the machine 502 with the use of only one headstock to drive the ram or provide the axial extrusion forces, which can help to reduce a cost of the machine 502.

[0083] FIG. 6 illustrates a cross-sectional isometric view of a portion of the shear- assisted extrusion system 502. The machine 502 can be consistent with the machine 502 discussed above. FIG. 6 shows additional details of the machine 502. For example, FIG. 6 shows that the headstock 540 can include a spindle 568 to which the tooling plate 548 can be secured. The spindle 568 can be rotatable (such as indicated by the arrow Rl) to rotate about the central axis Al. The tooling plate 548 and the die tool 554 can be rotatable with the spindle 568 relative to the midstock 542 (including the container 560) and relative to the ram 566.

[0084] The machine 502 can also include a base 570 to which various components of the machine 502 can be secured. The base 570 can be a rigid platform configured to support the components of the machine 502, such as the headstocks, actuators, and the like. The midstock 542 can include holes, bores, or slots 572a and 572b extending at least partially therein or therethrough to receive portions of rails 574a and 574b at least partially therein or therethrough such that the midstock 542 can translate along the rails 574a and 574b. The tailstock 544 can also include openings, slots, holes, bores, or the like configured to receive portions of rails 574a and 574b at least partially therein or therethrough to allow the tailstock 544 to translate relative to the rails 574a and 574b. The rails 574a and 574b can include 2 rails, 3 rails, 4 rails, 5 rails, 6 rails, 7 rails, 8 rails, 9 rails, 10 rails, or the like. The rails 574a and 574b can be rigid or semi-rigid elongate members (e.g, rods, bars, tubes, or the like) configured to support movable headstocks and other components of the machine 502 and can be configured to react to torsional loads of the machine 502.

[0085] The machine 502 can also include a lock 576 connected to the midstock 542 such as near the slot 572A that receives the rail 574A. The midstock 542 can optionally include a second lock near the slot 572B. The lock 576 can be user- operable (or controlled by the controller 405) to be movable between a locked position and an unlocked position. In the locked position, the lock 576 can engage the midstock or the rail 574A to restrict axial movement of the midstock 542. In the unlocked position of the lock 576, the midstock 542 can be free to move along the rails 574a and 574b relative to the headstock 540 and the tailstock 544. Optionally, the lock 576 can be configured to insert into bores 578 of the rail 574A. In otherexamples, the 576 can be a clamp, screw, or other device configured to limit axial translation of the midstock 542 along the rails when the lock 576 is in the locked position.

[0086] FIG. 7 illustrates a cross-sectional isometric view of a portion of a shear- assisted extrusion system 700 including a ShAPE machine 702. FIG. 8 illustrates a cross-sectional side view of a portion of a shear-assisted extrusion system including the ShAPE machine 702. FIGS. 7 and 8 are discussed together below. The ShAPE machine 702 can be similar to the any of the ShAPE machines discussed above, such as the machine 502. The ShAPE machine 702 can include a midstock including one or more actuators operable to translate the midstock. Any of the machines discussed above or below can include the features of the ShAPE machine 702.

[0087] Similar to the machine 502, the ShAPE machine 702 can include a headstock 740, a midstock 742, and a tailstock 744 where the headstock 740 can be axially fixed or nonmoving along the central axis A. Meanwhile, the midstock 742 can be translatable along the central axis relative to the headstock 740 and the tailstock 744. Similarly, the tailstock 744 can be translatable along the central axis relative to the headstock 740 and the headstock 740. The headstock 740, the midstock 742, and the tailstock 744 can be connected to one or more rails (e.g., a rail 774A) and the midstock 742 and the tailstock 744 can be translatable along the rail(s) 774A. Each of the headstock 740, the midstock 742, and the tailstock 744 can be supported by a base 770.

[0088] FIG. 7 also shows that the ShAPE machine 702 can include a spindle 768 connected to the headstock 740 and to the die tool (e.g., the die tool 554). The ShAPE machine 702 can also include one or more motors 780A and 780B, which can be connected to the spindle 768 via a gear 782 (or gearbox, one or more gears, or pulleys). The motors 780A and 780B can also be in communication with the controller 405 (or another controller) such that the controller 405 can operate the motors 780A and 780B. The gears 782 can be driven by the motors 780A and 780B by one or more gears, belts, or the like. The gear 782 can be directly connected or coupled to the spindle 768 such as to transfer rotation of the motors 780A and 780B to the spindle 768 and to the die tool (e.g., the die tool 554). The ShAPE machine 702 can also include one or more bearings 785A and 785B (which can be ball bearings, roller bearings, spherical roller thrust bearings, journal bearings, hydrodynamic bearings, hydrostatic bearings, fluid bearings, or the like) connected to (or engagedwith) the headstock 740 and the spindle 768 and configured to support rotation of the spindle 768 with respect to the headstock 740.

[0089] FIG. 7 further shows that the ShAPE machine 702 can include shafts 786A and 786B and actuators 788A and 788B. The actuators 788A and 788B can be connected to or in communication with the controller 405. The shafts 786A and 786B can connect to the headstock 740 and the midstock 742. The actuators 788A and 788B can be connected to or located at least partially within the midstock 742. The actuators 788A and 788B motors such as electric, hydraulic, combustion motors, or the like operable to move the shafts 786A and 786B. For example, the actuators 788A and 788B can be rotary motors, such as electric servos or variable frequency drive driven electric motors, but can be other motor types such as hydraulic or the like. The shafts 786A and 786B can be screws, such as lead screws, roller screws, electric cylinders, or ball screws. In operation of some examples, the controller 405 (or other controller) can operate the actuators 788A and 788B to translate the midstock 742 relative to the headstock 740 and the tailstock 744 along the rails 774 as indicate by the arrow T2. The actuators 788A and 788B can be sized to be relatively smaller than actuators of the tailstock 744 such that the tailstock 744 can generate or sustain the axial extrusion force and the actuators 788A and 788B can help provide extrusion force or can be operated for maintenance, loading, or other service or operation of the ShAPE machine 702.

[0090] The machine 502 can also include shafts 790 A and 790B and actuators 792A and 792B. The actuators 792A and 792B can be connected to or in communication with the controller 405. The shafts 790A and 790B can connect to the headstock 740 and the tailstock 744. The actuators 792A and 792B can be motors such as electric, hydraulic, or combustion motors operable to move the shafts 790A and 790B. For example, the actuators 792A and 792B can be rotary motors, such as electric servos or variable frequency drive driven electric motors, but can be other motor types such as hydraulic or the like. The shafts 790A and 790B can be screws, such as lead screws, roller screws, electric cylinders, or ball screws. In operation of some examples, the controller 405 (or other controller) can operate the actuators 792A and 792B to translate the tailstock 744 relative to the headstock 740 and the midstock 742 along the rails 774 as indicate by the arrow Tl, such as to drive a ram 766 (which can be similar to the ram 566) into a container 760 (which can be similar to the container 560) of the midstock 742 to engage a billet 746 (which can be similar to thebillet 546). The actuators 792A and 792B can be sized to generate or sustain the axial extrusion force or can be operated for maintenance, loading, or other service or operation of the ShAPE machine 702.

[0091] For example, as shown in FIG. 8, during setup or as one of the initial steps of an operation, the actuators 788A and 788B can be operated to translate the shafts 786A and 786B along the arrows T3 to move the midstock 742 towards the headstock 740 such that a die tool 784 (which can be similar to the die tool 554) can be inserted into a bore 764 of the container 760 to engage the billet 746. Thereafter, the motors 780A and 780B can be operated to rotate the spindle 768 and the die tool 784 to generate or sustain a rotational speed to generate a rotation-induced shear force at an interface between the billet 746 and the die tool 784. Also, the actuators 792A and 792B can be operated to translate the ram 766 into the bore 764 (as shown in FIG. 8) such as to engage the billet 746 to generate or sustain the axial shear force applied to the billet 746 and the die tool 784. The combination of the axial and the rotating forces can plasticize the billet 746 at the interface with the die tool 784. Flow of the plasticized material can then be directed, through the die tool 784 and through the spindle 768. Reconstitution of plasticized material can occur defining a hollowinterior extrudate using a direct ShAPE extrusion process. However, the machine 702 can also be used to generate solid extrudate, such as via friction stir extrusion or friction extrusion.

[0092] FIG. 9 illustrates a cross-sectional schematic view of a portion of a shear- assisted extrusion system 900 including a ShAPE machine 902. The ShAPE machine 902 can be (or can be similar to) the ShAPE machines 502 or 702 discussed above or any of the other ShAPE machines discussed above or below, such that the features of the machine 902 can be included in any of the ShAPE machines discussed above or below.

[0093] The machine 902 can include an endstock 940, a midstock 942, and a tailstock 944. The endstock 940, the midstock 942, and the tailstock 944 can be rigid or semi-rigid components configured to process feedstock or a billet 946. The endstock 940, the midstock 942, and the tailstock 944 can be configured to react linear and torsional forces of the machine 902, which may or may not be identical. The machine 902 can also include one or more tooling plates. For example, the endstock 940 can include a tooling plate 948 that can be secured to a rear portion of the endstock 940. The machine 902 can also include a tooling plate 950 secured to afront portion of the midstock 942 and the machine 902 can include a tooling plate 952 secured to a front portion of the tailstock 944. The tooling plate 950 can be rotatable with a spindle 969 of the midstock 942 and the tooling plate 952 can be rotatable with a spindle 971 of the tailstock 944.

[0094] The machine 902 can also include a die tool 954 including a die face 956 at a rear portion of the die tool 954 and the die tool 954 can include an opening 958 that can extend along the central axis A through the die tool 954. The die face 956 can be configured to engage and plasticize portions of the billet 946 engaged with the die face 956 and the opening 958 can receive plasticized material therethrough during extrusion operations.

[0095] The machine 902 can also include a container 960 located at (or connected to or adjacent to) a radially inner surface of the midstock 942. The container 960 can be connected to the spindle 969 or included in the midstock 942 and movable therewith, such as via a connection to the tooling plate 950. The container 960 can be configured to support the billet 946 at least partially therein. The machine 902 can also include a liner 962 that can include a bore 964, where the bore 964 can extend along the central axis A. The liner 962 can be located at (or connected to or adjacent to) a radially inner surface of the container 960. The liner 962 can be configured to engage and support the billet 946 within the bore 964 of the liner 962. The liner 962 can be releasably securable or secured to the container 960 such that the liner 962 is relatively easily replaceable.

[0096] FIG. 9 also shows that the machine 902 can include a ram 966 secured to the tooling plate 952 such that the ram 966 can be configured to extend at least partially into the bore 964 of the liner 962, allowing the ram 966 to engage the billet 946. The ram 966 can be translatable with the tailstock 944 such as along the central axis A as indicated by the arrow indicator T1 relative to the endstock 940 and the midstock 942. The midstock 942 (along with the container 960, the liner 962, and the billet 946) can also be translatable along the central axis A as indicated by the arrow indicator T2 relative to the endstock 940 and the tailstock 944.

[0097] The spindle 969 can be connected to a motor and configured to rotate about the central axis relative to the endstock 940 and the tailstock 944, as indicated by the arrow R2. Similarly, the spindle 971 can be connected to a motor and configured to rotate about the central axis relative to the endstock 940 and the midstock 942, as indicated by the arrow R1 such that the spindle 969 and the spindle 971 can rotatetogether to limit relative rotation of the ram 966 and the billet 946 during shear- assisted extrusion operations.

[0098] In operation of some examples, feedstock material (e.g., the billet 946) can be loaded into the bore 964 of the liner 962 and the die tool 954 can be secured to the tooling plate 948. When the feedstock material is loaded, the midstock 942 can then be moved into position where the die tool 954 is engaged with the billet 946. An extrusion process can begin where the spindle 969 can be rotated to rotate the billet 946 to establish a rotation-induced shear force at an interface between the die tool and the feedstock material. The spindle 971 can also be rotated to match a rotational speed of the spindle 969. The tailstock 944 can be translated (e.g., along the central axis A) to translate the ram 966 into the bore 964 to engage the billet 946 to establish an axial extrusion force. During extrusion, the rotating billet 946 can engage the die face 956 resulting in shear-assisted extrusion and generating plasticized material that can enter the opening 958. Reconstitution of plasticized material can occur downstream of the die face 956 (as discussed above) to generate extrudate which can include one or more desired characteristics.

[0099] Though the midstock 942 is shown and discussed as being translatable, the midstock 942 is not required to translate during extrusion, as the axial forces can be generated by the tailstock 944. The midstock 942 can also be translatable (manually or automatically) before or after a process such as for maintenance of the machine 902 or for loading or unloading of material, such as loading of the billet 946 into the bore 964 prior to the extrusion process.

[0100] FIG. 10 illustrates a cross-sectional isometric view of a portion of the shear- assisted extrusion system 900 including the machine 902. FIG. 11 illustrates a cross- sectional side view of a portion of the shear-assisted extrusion system 900 including the machine 902. FIG. 12 illustrates a cross-sectional side view of a portion of the shear-assisted extrusion system 900 including the machine 902. FIG. 13 illustrates a cross-sectional side view of a portion of the shear-assisted extrusion system 900 including the machine 902. FIGS. 10-13 are discussed together below. The machine 902 discussed in FIGS. 10-13 can be consistent with FIG. 9 discussed above. FIGS. 10-13 show additional details of the machine 902.

[0101] For example, FIG. 10 shows that the ShAPE machine 902 can include a spindle 969 connected to the container 960 and connected to the midstock 942. The ShAPE machine 902 can also include one or more motors 981 A and 98 IB, which canbe connected to the spindle 969 via a gear 982 (or gearbox, one or more gears, or pulley). The motors 981 A and 98 IB can also be in communication with the controller 405 (or another controller) such that the controller 405 can operate the motors 981 A and 98 IB. The gears 982 can be driven by the motors 981 A and 98 IB by one or more gears, belts, or the like. The gear 982 can be directly connected or coupled to the spindle 969 such as to transfer rotation of the motors 981 A and 98 IB to container 960 and the billet 946. The ShAPE machine 902 can also include one or more bearings 985 (which can be ball bearings, roller bearings, spherical roller thrust bearings, journal bearings, hydrodynamic bearings, hydrostatic bearings, fluid bearings, or the like) connected to (or engaged with) the endstock 940 and the spindle 969 and configured to support rotation of the spindle 969 with respect to the endstock 940. Each of the endstock 940, the midstock 942, and the tailstock 944 can be supported by a base 970.

[0102] The machine 902 can also include one or more motor 991 connected to the spindle 971 via a pulley and belt 993 (or gear or gears). The one or more motor 991 can be in communication with the controller 405 (or another controller) such that the controller 405 can operate the motor 991. The pulley 993 can be connected to the spindle 971 such that rotation of the one or more motor 991 can rotate the belt 993 and the spindle 971, which can rotate the ram 966. The machine 902 can also include one or more bearings 994 connected to the spindle 971 and the tailstock 944 and configured to support rotation of the spindle 971 with respect to the tailstock 944. The one or more bearings 994 can be ball bearings, roller bearings, spherical roller thrust bearings, journal bearings, hydrodynamic bearings, hydrostatic bearings, fluid bearings, or the like.

[0103] FIG. 10 further shows that the ShAPE machine 902 can include shafts 986A and 986B and actuators 988A and 988B. The actuators 988A and 988B can be connected to or in communication with the controller 405. The shafts 986 A and 986B can connect to the endstock 940 and the midstock 942. The actuators 988A and 988B can be connected to or located at least partially within the endstock 940. The actuators 988A and 988B can be motors such as electric, hydraulic, or combustion motors operable to move the shafts 986A and 986B. For example, the actuators 988 A and 988B can be hydraulic actuators or the like. The shafts 986A and 986B can be screws, such as lead screws, roller screws, electric cylinders, or ball screws. In operation of some examples, the controller 405 (or other controller) can operate the actuators 988Aand 988B to translate the midstock 942 relative to the endstock 940 and the tailstock 944 along the rails 974. The actuators 988A and 988B can be sized to be relatively smaller than actuators of the tailstock 944 such that acutators of the tailstock 944 can generate or sustain the axial extrusion force and the actuators 988A and 988B can help provide extrusion force or can be operated for maintenance, loading, or other service or operation of the ShAPE machine 902.

[0104] The machine 902 can also include shafts 990 A and 990B and actuators 992 A and 992B. The actuators 992 A and 992B can be connected to or in communication with the controller 405. The shafts 990 A and 990B can connect to the endstock 940 and the tailstock 944. The actuators 992A and 992B can be connected to or located at least partially within the tailstock 944. The actuators 992A and 992B can be motors such as electric, hydraulic, or combustion motors operable to move the shafts 990A and 990B. For example, the actuators 992A and 992B can be hydraulic actuators, or the like. The shafts 990A and 990B can be screws, such as lead screws, roller screws, electric cylinders, or ball screws. In operation of some examples, the controller 405 (or other controller) can operate the actuators 992A and 992B to translate the tailstock 944 relative to the endstock 940 and the midstock 942 along the rails 974, such as to drive the ram 966 into the container 960 of the midstock 942 to engage the billet 946. The actuators 992A and 992B can be sized to generate or sustain the axial extrusion force or can be operated for maintenance, loading, or other service or operation of the ShAPE machine 902.

[0105] For example, as shown in FIG. 11, during setup, the actuators 988A and 988B can be operated to move the midstock 942 away from the endstock 940 to allow the die tool 954 to be secured to the endstock 940 and the actuators 992A and 992B can be operated to move away from the midstock 942 to allow the billet 946 to be loaded into the container 960. Then, as shown in FIG. 12, the actuators 988A and 988B can be operated to translate the shafts 986A and 986B to move the midstock 942 towards the tailstock 944 such that a die tool 954 (which can be similar to the die tool 554) can be inserted into a bore 964 of the container 960 to engage the billet 946. And, as shown in FIG. 12, the actuators 992 A and 992B can be operated to translate the tailstock 944 and the ram 966 such that the ram 966 is inserted into the bore 964 such that the ram 966 is in contact with the billet 946 or is near the billet 946.

[0106] Thereafter, the motors 981 A and 98 IB can be operated to rotate the spindle 969, the container 960, and the billet 946 to generate or sustain a rotational speed togenerate a rotation-induced shear force at an interface between the billet 946 and the die tool 954. Also, the one or more motor 991 can be operated to rotate the spindle 971 and the ram 966 such that the ram 966 rotates at a speed that matches or is similar to the rotational speed of the billet 946 and the container 960. The rotating components are shown in FIG. 13.

[0107] The actuators 992A and 992B can be operated to translate the ram 966 to engage the billet 946 to generate or sustain the axial shear force applied to the billet 946 and the die tool 984 by the ram 966. The combination of the axial and the rotating forces can plasticize the billet 946 at the interface with the die tool 954. Flow of the plasticized material can then be directed, through the die tool 984 and through the spindle 968. Reconstitution of plasticized material can occur defining a hollowinterior extrudate that does not rotate during a direct ShAPE extrusion process.

[0108] FIG. 14 illustrates a cross-sectional side view of the endstock 940 of the machine 902. The endstock 940 of FIG. 14 can be consistent with FIGS. 9-13 discussed above. FIG. 14 shows additional details of the endstock 940. For example, FIG. 14 shows that the endstock 940 can include standoffs 995. Though FIG. 14 shows three standoffs, the endstock 940 can include 1, 2, 4, 5, 6, 7, 8, 9, 10, or the like. The standoffs 995 can be connected to or secured to a body 997 of the endstock 940 and can optionally be releasably secured to the body 997. The standoffs 995 can be configured to engage the midstock 942, such as when the midstock 942 is moved to insert the die tool 954 into the bore 964. By engaging the midstock 942, the standoffs 995 can provide a desired spacing between the midstock 942 and the endstock 940 and therefore between the die tool 954 and the billet 946 during extrusion operations. The standoffs 955 can provide axial or torsional load reaction between the endstock 940 and midstock, 942 such that the small actuators 986 / 988 do not themselves need to react very large axial processes forces. The standoffs 995 can be replaceable, such as based on a geometry or size of the die tool 954 to achieve a desired spacing between components.

[0109] FIG. 14 also shows that the endstock 940 can include bores 996A and 996B that can extend at least partially into the body 997 of the endstock 940. The bores 996A and 996B can be mounts configured to receive the shafts 990A and 990B, respectively, at least partially therein to secure the shafts 990A and 990B to the endstock 940, which can allow the tailstock 944 to be moved relative to the endstock940 when the shafts 990A and 990B are operated by the actuators 988A and 988B, respectively.

[0110] FIG. 15A illustrates a cross-sectional side view of a portion of the shear- assisted extrusion system 900. FIG. 15B illustrates a cross-sectional side view of the shear-assisted extrusion system 900. FIG. 15C illustrates a cross-sectional side view of the shear-assisted extrusion system 900. FIGS. 15A-15C are discussed together below. The shear-assisted extrusion system 900 can be similar to the shear-assisted extrusion system 900 discussed above. FIGS. 15A-15C show examples of how the shear-assisted extrusion system 900 can be operated.

[0111] More specifically, FIGS. 15A-15C show the shear-assisted extrusion system 900 in three configurations. FIG. 15A shows the ram 966 located at least partially within the liner 962 and engaged with the billet 946. FIG. 15B shows the ram 966 located further within the liner 962 that in FIG. 15B and engaged with the billet 946, where a portion of the billet 946 has been consumed. FIG. 15C shows the ram 966 located further within the liner 962 that in FIG. 15C and engaged with the billet 946, where a majority of the billet 946 (or larger portion than in FIG. 15B) has been consumed to generate or create extrudate through the die tool 954. As the ram 966 extends into the container 960 and the liner 962 (and as the billet 946 is consumed), both the spindle 969 of the midstock 942 and the spindle 971 of the tailstock 944 can rotate to generate torque applied to the to the interface between the billet 946 and the die tool 954. Because torque can be transferred from the ram 966 (from the spindle 971) to the billet 946, a total torque required to generate the rotation-induced shear extrusion between the die tool 954 and the billet 946 can be split between the spindle 969 and the spindle 971.

[0112] As shown in the table Tl, in FIG. 15 A, where the ram 966 first contacts the billet 946 and where a low percentage of the billet 946 has been consumed, nearly all of the torque can be generated or provided by the container 960 (from the spindle 969). As the billet 946 is consumed, as shown in FIG. 15B, such as up to when the billet 946 is mostly consumed, the container 960 and the ram 966 can each deliver a portion of the torque (provided by the spindle 969 and the spindle 971). For example, the container 960 can deliver between a majority to minority (such as 80 percent and 20 percent) of the torque and the ram 966 can deliver between a majority and a minority (such as 20 percent and 80) percent of the torque. As the billet 946 is further consumed, as shown in FIG. 15C, such as when the billet 946 is mostly consumed, thecontainer 960 and the ram 966 can each deliver a portion of the torque (provided by the spindle 969 and the spindle 971); however, the because only a small amount of the billet 946 remains, the required torque may not be able to be fully transferred between the container 960 and the billet 946. In such a case, the container 960 can deliver around a minority (such as 10 percent or less) of the torque and the ram 966 can deliver around the vast majority (such as 90 percent or more) of the torque. Such torque splitting or sharing between the spindles spindle 969 and spindle 971 can help to ensure that that a desired torque is delivered and that the torque does not exceed a desired operational torque for performing direct ShAPE.

[0113] FIG. 16 illustrates an example of a flowchart of a method 1600 for extruding pieces. The method 1600 can be a method of performing shear-assisted extrusion for extruding (for example) hollow cross-section pieces. More specific examples of the method 1600 are discussed below. The steps or operations of the method 1600 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 1600 as discussed includes operations performed by multiple different actors, devices, or systems. It is understood that subsets of the operations discussed in the method 1600 can be attributable to a single actor, device, or system could be considered a separate standalone process or method. The method 1600 may be carried out using an extrusion system such as the systems described in association with FIGS. 1 to 15. 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.

[0114] At step 1602, a machine can be set up by securing a die tool to a headstock and inserting billet or feedstock material into a canister. For example, the die tool 954 can be secured to the endstock 940 and the billet 946 can be inserted into the container 960. At step 1604, a machine can be started up by initiating spindle rotation. In the example of FIG. 7, the spindle 768 can be initiated to rotate the die tool 784. In the example of FIG. 9, the spindle 969 and the spindle 971 can be initiated to rotate the container 960, the bore 964, and the ram 966. At step 1606, the ram can be moved. For example, the ram 766 can be moved by translating the tailstock 744 from an offset position to a contact position where the ram 766 can engage a rear portion of the billet 746 and where the ram 766 is aligned along the central axis A. Similarly, the ram 966 can be moved by translating the tailstock 944.

[0115] At step 1608, the ram can be moved to contact a billet. For example, once the components are in alignment and positioned accordingly, contact between the ram 766 and the billet 746 can occur. At step 1610, ramp up can be performed. For example, an axial velocity of the ram 766 can be slowly increased (such as through adjusting the velocity of the tailstock 744), resulting in a rapid increase in force, power, and temperature of various components of the machine 702, such as the billet 746. At step 1612, speeds of the spindles can be controlled. For example, rotational speed of the front spindle 768 can be controlled (e.g., raised or lowered) to bring a process temperature to or near a desired process temperature. In the example of FIG. 9, the spindle 969 and spindle 971 can be controlled to a desired speed and to bring a process temperature to or near a desired process temperature. Additionally, the controller can balance rotational torque delivered by the spindle 969 and spindle 971 such as based on a depth of the ram 966 extending into the container 960 or a remaining amount of billet 946 (or a proximity of the ram 966 to the die tool 954).

[0116] At step 1614, steady state can be entered. After ramp up and obtaining a desired temperature, ramp up can be complete and steady state can be entered where the speed of the spindle or spindles can be maintained and the axial velocity of the rear the ram can be maintained, which can result in near-constant process temperatures and near-constant axial forces during direct ShAPE extrusion processes. In some examples, rotational speed of the spindle 969 and the spindle 971 can be adjusted or varied to maintain the desired process temperature while axial velocity of the tailstock 944 and the ram 966 can be maintained to maintain the desired axial force. Optionally, during steady state extrusion, the controller can balance rotational torque delivered by the spindle 969 and spindle 971 such as based on a depth of the ram 966 extending into the container 960 or a remaining amount of billet 946 (or a proximity of the ram 966 to the die tool 954).

[0117] At step 1616, velocities can be reduced following extrusion. For example, after the billet 746 is consumed or nearly consumed, an axial velocity of the ram 766 and the rotational velocity of the spindle 768 can be relatively quickly reduced to zero and then the velocity of the ram 766 can be reversed to back the ram 766 out of the bore 764. During stopping of extrusion and backing out of the ram 766, a speed of the spindle 768 can be reduced but not stopped, which can help to reduce adherence of the billet 746 to the other components of the machine 702. While the above describes one example of an extrusion process, these steps do not describe all extrusions. Forexample, a very slow extrusion may not need a ramp-up phase. And, the machines 702 and 902 can provide flexibility in its programming to accommodate various differences of operation.

[0118] FIG. 17 illustrates an isometric cross-sectional view of a portion of a friction stir extrusion machine 400. The extrusion machine 400 can be similar to the extrusion system 100, but can be configured for friction stir extrusion. The extrusion machine 400 can include a die assembly 410 and a billet holder assembly 412.

[0119] The billet holder assembly 412 can be similar to the billet holder assembly 112 in that the billet holder assembly 412 can include a container base 412A and a container sidewall 412B or jacket. The billet holder assembly 412 can also include a liner 432. The liner 432 can be connected to an inner surface of the container sidewall 412B. The liner 432 can be engageable with the feedstock and can support the feedstock material at least partially therein. The die assembly 410 can include a die shank 414 and a die holder 421 to which the die shank 414 can be secured. A die 422 can be connected to the die shank 414.

[0120] The extrusion machine 400 can also include a ram assembly 440 including a ram 442 and a stem 444 that can be connected to the ram 442 by features such as threaded portion 446 of the ram 442. The stem 444 can be guided by a bearing 448, which can be an anti-torsion bearing configured to help limit or resist torsion. The container base 412A can be bolted or otherwise secured to a spindle that can deliver rotational input to the billet holder assembly 412, such as the container base 412A. In some examples, the container base 412A can be bolted or otherwise secured to a nonrotating tailstock member that can resist torsional movement of the billet holder assembly 412, such as the container base 412A.

[0121] FIG. 17 also shows that the extrusion machine 400 can include a plurality of keys 450 that can be secured to the container base 412A. The plurality of keys 450 can be at least partially insertable into canister recesses 452. The billet holder assembly 412 (or the container sidewall 412B) can extend between a first canister end portion 454 and a second canister end portion 456 where the first canister end portion 454 is configured to receive the die 422 at least partially therein. The second canister end portion 456 can be located opposite the first canister end portion 454 and can be configured to receive the ram 442 at least partially therein. The canister recesses 452 can extend axially inward from an end surface of the second canister end portion 456. When the plurality of keys 450 are inserted at least partially into the canister recesses452, the container base 412A can deliver torque or cause the container sidewall 412B to rotate with the container base 412A.

[0122] Similarly, the liner 432 can extend between a first liner end portion 458 and a second liner end portion 460. The first liner end portion 458 can be configured to receive a friction stir extrusion or porthole die 422 at least partially therein. The second liner end portion 460 can be located opposite the first canister end portion 454 and can be configured to receive the ram 442 at least partially therein. The liner 432 can also include liner recesses 462 that can extend at least partially into the second liner end portion 460 to form a torque interface 463. The torque interface 463 can be configured to mate or interface with the container base 412A or the spindle to receive torque therefrom.

[0123] The plurality of keys 450 can be at least partially insertable into the liner recesses 462. When the plurality of keys 450 are inserted at least partially into the liner recesses 462, the container base 412A can deliver torque or cause the liner 432 to rotate or remain rotationally fixed with the container base 412A. Each of the canister recesses 452 can be in radial alignment with one of the liner recesses 462 to allow pairs of the canister recesses 452 and the liner recesses 462 to receive a common one of the plurality of keys 450 at least partially therein.

[0124] FIG. 17 also shows that the plurality of keys 450 can include a fastener bore 464 and the container base 412A can include a fastener bore 466 that can be aligned with the fastener bore 464 of the plurality of keys 450 to receive a fastener 468 at least partially therein to releasably secure the plurality of keys 450 to the container base 412A. In this way, the relatively small keys plurality of keys 450 can be easily replaced if damaged or worn.

[0125] In operation of some examples, the billet holder assembly 412 can support feedstock material at least partially therein, such as within the liner 432. The container base 412A can be driven to rotate along with the ram 442. The container base 412A can drive the container sidewall 412B and the liner 432 to rotate with the container base 412A via the plurality of keys 450 through the canister recesses 452 and the liner recesses 462. The die 422 can maintain a rotational position during extruding. Alternatively, the die 422 can rotate during extruding if the billet holder assembly 412 is rotationally stationary.

[0126] The ram 442 can then be translated by the stem 444 to such that the billet material engages the die 422 such that the axial movement of the ram 442 and therotation of the billet holder assembly 412 can create a rotation-induced shear force between the feedstock material and the die 422 to plasticize the feedstock material at or adjacent to the interface between the die 422 and the billet material. The plasticized material can flow through a bore 426 of the die 422 and can exit the bore 426 as solid extrudate in a friction stir extrusion process. Such a system can allow for the liner 432 to be both replaceable and to receive rotation and torque from a spindle through replaceable keys, allowing for individually replaceable components to be used in an assembly that rotates together.

[0127] FIG. 18 illustrates an isometric view of the liner 432 of the extrusion machine 400. The extrusion machine 400 can be consistent with FIG. 17 discussed above. FIG. 18 shows additional details of the liner 432. For example, FIG. 18 shows more clearly how the liner 432 can include multiple recesses 462, such as four recesses 462A-462B, which can be evenly spaced around a circumference of the liner 432. Though 4 recesses are shown, the liner 432 can include 1, 2, 3, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, or 20 recesses. FIG. 18 also shows how the recesses 462 can extend inward from the second liner end portion 460 toward the first liner end portion 458. The liner recesses 462 can be evenly spaced around the circumference of the liner 432 such as to help evenly distributed forces, but the liner recesses 462 can be asymmetrically spaced in other examples. FIG. 18 also more clearly shows a bore 469 of the liner configured to receive feedstock material at least partially therein.

[0128] FIG. 19 illustrates an isometric view of a spacer 470 of the extrusion machine. The spacer 470 can include a body 472 extending between a first end portion 474 and a second end portion 476 opposite the first end portion 474. The spacer 470 can include a plurality of bosses 480 extending from the first end portion 474 (away from the second end portion 476). The spacer 470 can also include a plurality of spacer recesses 478 extending into the second end portion 476. The plurality of keys 450 can be at least partially insertable into respective ones of the plurality of spacer recesses 478. Also, the plurality of bosses 480 can be insertable into the liner recesses 462.

[0129] In operation of some examples, such as when the first liner end portion 458 is worn down from use in one or more operations, the first liner end portion 458 can be reused by adding the spacer 470 to the extrusion machine 400. The liner 432 can be reduced in length from the first liner end portion 458 by a length of the spacer 470 and the spacer 470 can be inserted into the billet holder assembly 412 adjacent thesecond liner end portion 460. The plurality of bosses 480 can be inserted into the liner recesses 462 and the plurality of keys 450 can be inserted into respective ones of the plurality of spacer recesses 478 to allow the container base 412A to drive the spacer 470 to rotate together with the container 412. In this way, the liner 432 and the spacer 470 can work together to act as a single liner component in operation (in support of feedstock material) while allowing a lifetime of the liner 432 or a number of uses of the liner 432 to be extended, helping to reduce operational costs. A maximum length of the billet or feedstock can be reduced by a length of the spacer 470 depending on the system configuration.

[0130] FIG. 19 also shows that the plurality of bosses 480 and the plurality of spacer recesses 478 can be circumferentially offset of each other, which can help to reduce stress in the body 472 of the spacer 470. Though 4 recesses and bosses are shown, the spacer 470 can include 1, 2, 3, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, or 20 recesses and bosses. Also, though the spacer 470 is shown as having the same number of recesses and bosses (four of each), the spacer 470 can have more recesses than bosses.

[0131] FIG. 20 illustrates an isometric view of a liner 732 of an extrusion machine. The liner 732 can be configured to operate with an extrusion machine, such as the extrusion system 100 or the extrusion machine 400. Any of the extrusion machines discussed above or below can be configured to use the liner 732.

[0132] The liner 732 can be similar to the liner 432 discussed above such that the liner 732 can be positionable within the billet holder assembly 412 and can be configured to support feedstock material at least partially therein. And the liner 732 can be rotatable with the billet holder assembly 412 to perform friction stir extrusion (or can be used for ShAPE). The liner 732 can also include a bore 782 that can extend at least partially through the liner 732 and can be configured to receive a pin or other fastener at least partially therein. The pin and bore 782 can be used to secure the liner 732 to the billet holder assembly 412 to allow the liner 732 to rotate together with the billet holder assembly 412.

[0133] FIG. 21 illustrates an isometric view of a liner 832 of an extrusion machine. The liner 832 can be configured to operate with an extrusion machine, such as the extrusion system 100 or the extrusion machine 400. Any of the extrusion machines discussed above or below can be configured to use the liner 832.

[0134] The liner 832 can be similar to the liner 432 discussed above such that the liner 832 can be positionable within the billet holder assembly 412 and can be configured to support feedstock material at least partially therein. And the liner 832 can be rotatable with the billet holder assembly 412 to perform friction stir extrusion (or can be used for ShAPE). The liner 832 can also include outer faces 884 that can extend between the end portions of the liner 832 such that the liner 832 can have a shape of a hexagonal prism (or a hollow hexagonal prism due to the internal bore). The outer surfaces or faces 884 can be configured to engage with internal faces or surface of the billet holder assembly 412 that are similarly shaped and can limit or prevent both lateral movement and relative rotation of the liner 832 with respect to the billet holder assembly 412 to help ensure that the liner 832 rotates with the billet holder assembly 412.

[0135] FIG. 22 illustrates an isometric view of a liner 932 of an extrusion machine. The liner 932 can be configured to operate with an extrusion machine, such as the extrusion system 100 or the extrusion machine 400. Any of the extrusion machines discussed above or below can be configured to use the liner 932.

[0136] The liner 932 can be similar to the liner 432 discussed above such that the liner 932 can be positionable within the billet holder assembly 412 and can be configured to support feedstock material at least partially therein. And the liner 932 can be rotatable with the billet holder assembly 412 to perform friction stir extrusion (or can be used for ShAPE). The liner 932 can also include outer faces 984 that can extend between the end portions of the liner 932 such that the liner 932 can have a shape of an octagonal prism (or a hollow octagonal prism due to the internal bore). The outer surfaces or faces 984 can be configured to engage with internal faces or surface of the billet holder assembly 412 that are similarly shaped and can limit or prevent relatively rotation of the liner 932 with respect to the billet holder assembly 412 to help ensure that the liner 932 rotates with the billet holder assembly 412. Though FIG. 21 shows that the liner 832 can have 6 outer faces or surfaces and FIG. 22 shows that the liner 932 can have 8 outer faces or surfaces, the lines can have fewer or more faces, such as 3, 4, 5, 7, 9, 10, 11, 12, or the like. These faces 984 can be planar as depicted or may be non-flat surfaces.

[0137] FIG. 23 illustrates an isometric view of a liner 1032 of an extrusion machine. The liner 1032 can be configured to operate with an extrusion machine, suchas the extrusion system 100 or the extrusion machine 400. Any of the extrusion machines discussed above or below can be configured to use the liner 1032.

[0138] The liner 1032 can be similar to the liner 432 discussed above such that the liner 1032 can be positionable within the billet holder assembly 412 and can be configured to support feedstock material at least partially therein. And, the liner 1032 can be rotatable with the billet holder assembly 412 to perform friction stir extrusion (or can be used for ShAPE). The liner 1032 can also include a body 1057 extending between a first liner end portion 1058 and a second liner end portion 1060 where the body 1057 can be configured to support feedstock material at least partially therein. The body 1057 may not be able to, by itself, react to torsional forces, but the body 105 can react to internal pressures into the billet holder assembly 412 as well as prevent or limit lateral displacement within the billet holder assembly.

[0139] The liner 1032 can also include a torque interface 1086 connected to the second liner end portion 1060. The torque interface 1086 can also be a portion of the second liner end portion 1060. The torque interface 1086 can be sized and shaped to interface with the container base 412A or the spindle (such as a portion thereof that is shaped complimentary to the torque interface 1086) to receive torque or rotational input therefrom such that the liner 1032 can rotate with the billet holder assembly 412. As shown in FIG. 23, the torque interface 1086 can have a shape of a hexagonal prism (e.g., including 6 outer surfaces or faces) but can have other shapes in other examples, such as a square prism, a rectangular prism, or an octagonal prism. For example, the torque interface 1086 can have 3, 4, 5, 7, 8, 9, 10, 11, 12, 13, 14, or 15 faces. The torque interface 1086 can have a relatively short length relative to the body 1057 or can have a length that is a relatively small portion of the body 1057.

[0140] FIG. 24 illustrates an isometric view of a liner 1132 of an extrusion machine. The liner 1132 can be configured to operate with an extrusion machine, such as the extrusion system 100 or the extrusion machine 400. Any of the extrusion machines discussed above or below can be configured to use the liner 1132.

[0141] The liner 1132 can be similar to the liner 432 discussed above such that the liner 1132 can be positionable within the billet holder assembly 412 and can be configured to support feedstock material at least partially therein. And, the liner 1132 can be rotatable with the billet holder assembly 412 to perform friction stir extrusion (or can be used for ShAPE). The liner 1132 can also include a body 1057 extendingbetween a first liner end portion 1158 and a second liner end portion 1160 where the body 1157 can be configured to support feedstock material at least partially therein.

[0142] The liner 1132 can also include a torque interface 1186 connected to the second liner end portion 1060. The torque interface 1186 can also be a portion of the second liner end portion 1160. The torque interface 1186 can be sized and shaped to interface with the container base 412A or the spindle (such as a portion thereof that is shaped complimentary to the torque interface 1186) to receive torque or rotational input therefrom such that the liner 1132 can rotate with the billet holder assembly 412. As shown in FIG. 24, the torque interface 1186 can have a shape of a gear including teeth 1188. Though the torque interface 1186 is shaped as an external spur gear, the torque interface 1186 can be in the shape of other gear types such as an internal gear, a helical gear, a screw gear, a spline, or the like. A density of the torsional capacity of the torque interface 1186 can be higher than other configurations.

[0143] FIG. 25 illustrates an isometric view of a liner 1232 of an extrusion machine. The liner 1232 can be configured to operate with an extrusion machine, such as the extrusion system 100 or the extrusion machine 400. Any of the extrusion machines discussed above or below can be configured to use the liner 1232.

[0144] The liner 1232 can be similar to the liner 1232 discussed above such that the liner 1232 can be positionable within the billet holder assembly 412 and can be configured to support feedstock material at least partially therein. And, the liner 1232 can be rotatable with the billet holder assembly 412 to perform friction stir extrusion (or can be used for ShAPE). The liner 1232 can also include a body 1257 extending between a first liner end portion 1258 and a second liner end portion 1260 where the body 1257 can be configured to support feedstock material at least partially therein.

[0145] The liner 1232 can be similar to the liner 1032 in that the liner 1232 can include a torque interface 1286 that is a hexagonal prism (or other similar shape); the torque interface 1286 can include a bore 1290 extending at least partially through the torque interface 1286, such as through multiple faces thereof. The bore 1290 can be configured to receive a pin or other fastener at least partially therein or therethrough. The pin and bore 1290 can be used to secure the liner 1232 to the billet holder assembly 412 to allow the liner 1232 to rotate together with the billet holder assembly 412. The pin and bore 1290 can also be used be used to secure the liner 1232 to ininternally held mandrel in the billet holder assembly 412 for a drawn-over-mandrel extrusion approach.

[0146] FIG. 26 illustrates an isometric view of a liner 1332 of an extrusion machine. The liner 1332 can be configured to operate with an extrusion machine, such as the extrusion system 100 or the extrusion machine 400. Any of the extrusion machines discussed above or below can be configured to use the liner 1332.

[0147] The liner 1332 can be similar to the liner 432 discussed above such that the liner 1332 can be positionable within the billet holder assembly 412 and can be configured to support feedstock material at least partially therein. And, the liner 1332 can be rotatable with the billet holder assembly 412 to perform friction stir extrusion (or can be used for ShAPE). The liner 1332 can also include a body 1357 extending between a first liner end portion 1358 and a second liner end portion 1360 where the body 1357 can be configured to support feedstock material at least partially therein.

[0148] The liner 1332 can also include a torque interface 1386 connected to the second liner end portion 1360. The torque interface 1386 can also be a portion of the second liner end portion 1360. The torque interface 1386 can be sized and shaped to interface with the container base 412A or the spindle (such as a portion thereof that is shaped complimentary to the torque interface 1386) to receive torque or rotational input therefrom such that the liner 1332 can rotate with the billet holder assembly 412. As shown in FIG. 26, the torque interface 1386 can have an irregular or asymmetric shape. For example, the torque interface 1386 can have 3, 4, 5, 7, 8, 9, 10, 11, 12, 13, 14, or 15 faces that are asymmetrically or irregularly arranged. Faces can be planar or curved, and can be arranged relative to each other in convex, concave, or both concave and convex arrangements.

[0149] Any of the liners discussed above or below can be used in either direct or indirect extrusion systems or processes.

[0150] FIG. 27 illustrates an isometric cross-sectional schematic view of an extrusion machine 1400. The extrusion machine 1400 can be similar to the extrusion machine 400 such that like numerals can represent like components.

[0151] The extrusion machine 1400 can be similarly configured to the extrusion machine 400; a liner 1432 can include recesses 1462 located at a first liner end portion 1458 (opposite a second liner end portion 1460). The recesses 1462 can be configured to receive one or more key or projection 1450 connected to a containersidewall 1412B of a container 1412. The projection 1450 can be used in lieu of or in addition to keys and recesses at the second liner end portion 1460.

[0152] FIG. 28 illustrates an isometric cross-sectional view of an extrusion machine 2802, which can be (or can be part of) a shear extrusion system 2800. The extrusion machine 2802 can be similar to any of the machines or systems discussed above and any of the extrusion systems discussed above or below can include the features of the extrusion machine 2802.

[0153] The machine 2802 can include an endstock 2840, a midstock 2842, and a tailstock 2844. The endstock 2840, the midstock 2842, and the tailstock 2844 can be rigid or semi-rigid components configured to process feedstock or a billet 2846. The endstock 2840, the midstock 2842, and the tailstock 2844 can be configured to react linear and torsional forces of the machine 2802, which can be identical. The machine 2802 can also include one or more tooling plates. For example, the endstock 2840 can include a tooling plate 2848 that can be secured to a rear portion of the endstock 2840. The tooling plate 2848 can be a die holder, plate, or the like.

[0154] The machine 2802 can also include a die tool 2854 including a die face 2856 and a rear portion of the die tool 2854 and the die tool 2854 can include an opening 2858 that can extend along the central axis A through the die tool 2854. The die tool 2854 can be secured to the tooling plate 2848. The die face 2856 can be configured to engage and plasticize portions of the billet 2846 engaged with the die face 2856, and the opening 2858 can receive plasticized material therethrough during extrusion operations.

[0155] The machine 2802 can also include a container 2860 located at (or connected to or adjacent to) a radially inner surface of the midstock 2842. The container 2860 can be connected to a spindle 2869 or can itself be the spindle component (as shown in this embodiment) included in the midstock 2842 and movable therewith. The container 2860 can be configured to support the billet 2846 at least partially therein. The spindle 2869 can be engaged with one or more bearings 2871 engaged with a housing 2873 of the midstock 2842. The bearings 2871 can enable rotation of the spindle 2869, the container 2860, and the liner 2862 with respect to the housing 2873 and the carriage 2870. The spindle 2869 can be connected to or supported by a carriage 2870, which can be or can include one or more plates or structural members configured to connect the spindle 2869 or housing 2873 to one ormore rails of the machine 2802 such that the midstock 2842 can translate relative to the tooling plate 2848.

[0156] The machine 2802 can also include a liner 2862 that can include a bore 2864, where the bore 2864 can extend along the central axis A. The liner 2862 can be located at (or connected to or adjacent to) a radially inner surface of the container 2860. The liner 2862 can be configured to engage and support the billet 2846 within the bore 2864 of the liner 2862. The liner 2862 can be releasably securable or secured to the container 2860 such that the liner 2862 is replaceable.

[0157] The machine 2802 can also include a ram stem 2866 connected to a stem holder 2868 (e.g., together a ram), which can be configured to extend at least partially into the bore 2864 of the liner 2862, allowing the ram stem 2866 to engage the billet 2846. The ram stem 2866 can be translatable with the tailstock 2844 such as along the central axis A relative to the endstock 2840 and the midstock 2842. The midstock 2842 (along with the container 2860, the liner 2862, and the billet 2846) can also be translatable along the central axis A relative to the endstock 2840 and the tailstock 2844. The shear-assisted extrusion system 2800 can also include a coupling assembly 2872 connected to the container 2860 and the liner 2862 to allow the liner 2862 to be removed from the container 2860 and to allow the ram stem 2866 to interface with the liner 2862, as discussed in further detail below.

[0158] FIG. 28 also shows that the shear-assisted extrusion system 2800 can include standoffs 2855 that can be connected to or secured to (e.g., releasably securable to) the tooling plate 2848. The standoffs 2855 can be configured to engage the midstock 2842 (e.g., the carriage 2870) such as when the midstock 2842 is moved to insert the die tool 2854 into the bore 2864. By engaging the midstock 2842, the standoffs 2855 can provide a desired spacing between the midstock 2842 and the endstock 2840 and therefore between the die tool 2854 and the billet 2846 during extrusion operations. The standoffs 2855 can provide axial or torsional load reaction between the endstock 2840 and midstock 2842. The standoffs 2855 can be replaceable, such as based on a geometry or size of the die tool 2854 to achieve a desired spacing between components. The endstock 2840 can include 1, 2, 4, 5, 6, 7, 8, 9, 10, 15, 20 standoffs 2855, or the like. The standoffs 2855 can be comprised of a single piece or multiple pieces.

[0159] In operation of some examples, feedstock material (e.g., the billet 2846) can be loaded into the bore 2864 of the liner 2862 and the die tool 2854 can be secured tothe tooling plate 2848. When the feedstock material is loaded, the midstock 2842 can then be moved into position where the die tool 2854 is engaged with the billet 2846. The die tool 2854 can be axially and rotationally fixed with respect to the container 2860 and the ram stem 2866 during extruding. As discussed in further detail below, the ram stem 2866 can be insertable into the liner 2862 to interlock the ram and the container with the coupling assembly 2872. The tailstock 2844 can be connected to a motor and configured to rotate about the central axis relative to the tailstock 2844, as indicated by the arrow R.

[0160] An extrusion process can begin where the tailstock 2844 can be rotated to rotate the ram stem 2866 to rotate the container 2860 and the billet 2846 to establish a rotation-induced shear force at an interface between the die tool and the feedstock material. The tailstock 2844 can be translated (e.g., along the central axis A) to translate the ram stem 2866 into the bore 2864 to engage the billet 2846 to establish an axial extrusion force. During extrusion, the rotating billet 2846 can engage the die face 2856 resulting in shear-assisted extrusion and generating plasticized material that can enter the opening 2858. Reconstitution of plasticized material can occur downstream of the die face 2856 to generate extrudate which can include one or more desired characteristics. Because the ram stem 2866 can be interlocked to the liner 2862, the ram stem 2866 can drive the liner 2862 and the container 2860 to rotate about the central axis A. In this way, the machine 2802 need not include a motor to drive the container 2860. As discussed in further detail below, the container 2860 can be driven to rotate by a motor, which can also drive the ram stem 2866 to rotate via the coupling device(s) discussed above.

[0161] Though the midstock 2842 is shown and discussed as being translatable, the midstock 2842 is not required to translate during extrusion, as the axial forces can be generated by the tailstock 2844, in which can the axial forces may be transferred from the midstock 2842 to the endstock 2840 via standoffs 2855. The midstock 2842 can also be translatable (manually or automatically) before or after a process such as for maintenance of the machine 2802 or for loading or unloading of material, such as loading of the billet 2846 into the bore 2864 or the loading of the die 2854 into the tooling plate 2848 prior to the extrusion process.

[0162] FIG. 29 illustrates an isometric cross-sectional view of a portion of the extrusion machine 2802. FIG. 30 illustrates an isometric exploded view a portion of the extrusion machine 2802. FIGS. 29 and 30 are discussed together below. Theshear-assisted extrusion system 2800 and the machine 2802 of FIGS. 29 and 30 can be consistent with the shear-assisted extrusion system 2800 and the machine 2802 discussed above. FIGS. 29 and 30 show further details of the coupling assembly 2872.

[0163] For example, FIGS. 29 and 30 show that the coupling assembly 2872 can include a bushing or bearing 2876, a thrust coupler 2878, and a torsion coupler 2880. The bearing 2876 can be made of brass, copper, steel, or the like. The bearing 2876 can include an inner surface 2875 (FIG. 30) that can be shaped complimentary to (e.g., configured to mate with) an outer surface 2882 (FIG. 30) of the ram stem 2866. For example, the inner surface 2875 and the outer surface 2882 can have hexagonal shapes, but can be other shapes in other examples, such as rectangular, spline, octagonal, or the like. The bearing 2876 can include an outer surface 2877 (FIG. 30) that can be shaped complimentary to (e.g., configured to mate with) an inner surface 2863 (FIG. 30) of the liner 2862. This arrangement can allow the bearing 2876 to translate along the ram stem 2866 and to insert into the inner surface 2863. The ram stem 2866 can also include a head 2884 configured to engage the billet 2846 or to limit translation of the bearing 2876 with respect to the ram stem 2866.

[0164] The bearing 2876 can be translatable with the stem between an engaged position (shown in FIG. 30) and a disengaged position. In the engaged position, because the outer surface 2877 is insertable and complimentary to the inner surface inner surface 2863, the bearing 2876 can transfer rotation from the ram stem 2866 to the liner 2862 such as to drive the liner 2862 and the container 2860 to rotate with the ram stem 2866. In the disengaged position, the ram stem 2866 can be uncoupled from the liner 2862. In some examples, the bearing can be fused (or integrally formed) with the rear of the ram stem 2866 such that it rotationally interlocks with the liner 2862 near the end of the stroke.

[0165] The thrust coupler 2878 can be a connector, coupler, fastener, or the like. As shown in FIG. 29, the thrust coupler 2878 can be securable to an interlocking interface portion 2865 (FIG. 30) of the liner 2862 to secure the thrust coupler 2878 to the liner 2862. This interlocking interface portion 2865 can be a threaded portion, one or more axial splines, square threads, or other selectively releasable interfering geometry. As also shown in FIG. 29, the thrust coupler 2878 can engaged the container 2860, which can help to limit relative movement of the liner 2862 with respect to the container 2860 during extruding. As discussed below, the thrust coupler2878 can be releasable from the liner 2862.

[0166] FIGS. 29 and 30 also show that the torsion coupler 2880 can be secured to the liner 2862 and the container 2860. The torsion coupler 2880 can include a recess 2886 (FIG. 30) that can extend axially inward from one face toward an opposite face of the torsion coupler 2880. The recess can be shaped complementary to (e.g., configured to mate with) a projection 2888 (FIG. 30) of the liner 2862. In some examples, the projection 2888 can be a hexagonal prism and the recess 2886 can be a hexagonal recess. In other examples, the projection 2888 can have a shape of a rectangular or octagonal prism. Such an interface can allow or cause the torsion coupler 2880 to rotate with the liner 2862. In the case that the outside of the thrust coupler 2878 has the same nominal geometry as the container 2860, then the recess 2866 can be a single prism projection as shown. In some examples, the geometry of the liner projection 2888 can be different from the exterior of the thrust coupling 2878, and in such an example the torsional couple 2880 recess 2886 can including multiple negative projections.

[0167] FIGS. 29 and 30 also show that the torsion coupler 2880 can includes bores 2890 extending at least partially therethrough and configured to receive fasteners 2892 (FIG. 29) at least partially therethrough. The fasteners 2892 can be bolts, screws, or the like. The bores 2890 can be configured to be aligned with bores 2894 (FIG. 30) of the thrust coupler 2878 such that the fasteners 2892 extend at least partially through the bores 2890 and the bores 2894 and at least partially into bores 2896 (FIG. 31) of the container 2860, thereby securing the recess 2886 to the liner 2862 and the container 2860 to help limit relative rotation of the liner 2862 and the container 2860. The fasteners 2892 can also be removable to allow for the coupling assembly 2872 to be removed from the container 2860 and the liner 2862, as discussed in further detail below.

[0168] FIG. 31 illustrates an isometric cross-sectional view of a portion of the extrusion machine 2800. The shear-assisted extrusion system 2800 of FIG. 31 can be consistent with the shear-assisted extrusion system 2800 discussed above. FIG. 31 shows how the liner 2862 can be disconnected from the container 2860.

[0169] As discussed above, the coupling assembly 2872 can be removable from the container 2860 and the liner 2862. More specifically, the torsion coupler 2880 can be unbolted from the container 2860 to allow the torsion coupler 2880 to be removed from the liner 2862. Then, the thrust coupler 2878 can be removed or unthreaded from the liner 2862 and the thrust coupler 2878 can be removed from the liner 2862. Theram stem 2866 and the bearing 2876 can be moved away from the container 2860 and the liner 2862. This can allow the container 2860 to be separated from the liner 2862 such that when the container 2860 is translated or moved axially away from the tooling plate 2848 and the die tool 2854, the container 2860 and the liner 2862 can be separated, as shown in FIG. 31. This can be used to service the die tool 2854 or the liner 2862 such as when if the die tool 2854 and the liner 2862 or the billet 2846 seize together during operation(s).

[0170] FIG. 31 also shows that the shear-assisted extrusion system 2800 can include a cooling system 2898 that can be connected to the tailstock 2844. The cooling system 2898 can include a mounting plate 2899 that can be connected to the carriage 2870 or the housing 2873. The cooling system 2898 is discussed in further detail below.

[0171] FIG. 32 illustrates an isometric cross-sectional view of a portion of an extrusion machine, including the cooling system 2898. The cooling system 2898 can include a body 2881 including an inlet 2883 and an outlet 2885 connected to a cooling channel 2887 (or cooling path, flow path, channel, passageway, or the like). The cooling system 2898 can also include a seal 2889 connected to the body 2881 and at least partially defining the cooling channel 2887. The seal 2889 can form a seal between the cooling channel 2887 and an outer surface 2861 of the container 2860. As discussed above, the cooling system 2898 (or cooling sleeve) can be connected to the housing of the housing 2873 of the tailstock 2844.

[0172] During operation of some examples, the inlet 2883 can received fluid (e.g., air, oil, water, glycol, refrigerant, or the like) therein to allow the fluid to pass through the cooling channel 2887 and into contact with the outer surface 2861 of the container 2860, and the fluid can exit the outlet 2885 after exchanging heat with (e.g., cooling) one or more of the billet 2846, the container 2860, and the liner 2862. The fluid can contact the outer surface 2861 including when the container 2860 is rotating. During extruding, the container 2860 can be rotatable with respect to the body 2881 and the seal 2889, where the seal 2887 can form a rotating seal with the outer surface 2861 such as to retain fluid within the cooling channel 2887. In this way, the cooling system 2898 can be relatively simple in structure while being effective to cool the billet 2846, the container 2860, or the liner 2862.

[0173] FIG. 33 illustrates an isometric cross-sectional view of a portion of the shear-assisted extrusion system 2800 and the machine 2802. FIG. 34 illustrates anisometric view of a portion of the machine 2802 extrusion machine. FIGS. 33 and 34 are discussed together below. The shear-assisted extrusion system 2800 and the machine 2802 can be consistent with the shear-assisted extrusion system 2800 discussed above. FIGS. 33 and 34 show additional details of the shear-assisted extrusion system 2800 and machine 2802, such as of the standoffs 2855.

[0174] FIG. 34 shows that each of the standoffs 2855 can include one or more sensor(s) 2874 connected thereto. The sensor 2874 can be a sensor configured to generate a signal and transmit the signal to a controller based on one or more conditions of the standoffs 2855 or other nearby condition. For example, the sensor 2874 can be a force sensor or strain gauge configured to generate a signal based on an amount of force applied to the standoffs 2855, such as an axial force or torsional force or other reaction forces caused by the axial extrusion force between the die holder 2848 and the housing 2873 of the container 2860. In some examples, the standoffs 2855 can be made of a material with high ratio of strength to elastic modulus, such as aluminum, to allow the sensor 2874 to have a relatively higher resolution, such as due to increased elastic deformation of aluminum (e.g., compared to steel) during extrusion operations.

[0175] FIG. 34 also shows that the standoffs 2855 can include a first portion 2891 and a second portion 2893 that can be secured or connected using one or more fasteners 2895, which can be screws bolts, or the like, and can be optionally removable to allow the first portion 2891 and the first portion 2891 to be separated from each other. This two-piece construction can allow the standoffs 2855 to be used to establish different offsets of the tailstock 2844 from the tooling plate 2848 during extruding operations, such that the shear-assisted extrusion system 2800 can use different die tools. In other words, the second portion 2893 can be releasable from the first portion 2891 to reduce a distance between the container 2860 and the die holder 2848 when the housing 2873 of the container 2860 engages the plurality of standoffs 2855. In this setup, the sensors 2874 can remain attached to the first portion 2891 and do not need to be rewired, calibrated, or the like after swapping the second portion 2893. Various lengths of the second portion 2893 can be made such as 10, 11, 12, 13, 14, 15, 16, or 17 mm or the like in length.

[0176] FIG. 34 also shows that the standoffs 2855 can include an extraction bore 2897 extending at least partially into the standoffs 2855. The extraction bore 2897 can receive an extraction screw or extraction bolt 2831 at least partially therein where theextraction bolt 2831 can also extend through the carriage 2870 or the housing 2873 and can apply a force to help separate components of the shear-assisted extrusion system 2800 such as the die tool 2854 from the liner 2862. In another example, the extraction bore 2897 can receive the extraction bolt 2831 at least partially therein where the extraction bolt 2831 can also extend through the carriage 2870 or the housing 2873

[0177] FIG. 35 illustrates an isometric view of a portion of the extrusion machine 2802. FIG. 36 illustrates an isometric cross-sectional view of a portion of the extrusion machine 2802. The shear-assisted extrusion system 2800 and the machine 2802 of FIGS. 35 and 36 can be consistent with the shear-assisted extrusion system 2800 discussed above. FIGS. 35 and 36 show additional details of the shear-assisted extrusion system 2800 and machine 2802, such as pads 3500.

[0178] The pads 3500 can be connected to the carriage 2870 such as to connect the tailstock 2844 to rails, which can be linear rails. The pads 3500 can include a first plate 3502, a second plate 3504, and guides 3506. The first plate 3502 and the second plate 3504 can be connected to the carriage 2870 and the guides 3506 can be connected to the first plate 3502 and the second plate 3504 and can be configured to support the pads 3500 on one or more rails such as to allow the pads 3500 to translate or move along the rails.

[0179] The pads 3500 can also be configured to receive shims between the first plate 3502 and the second plate 3504. For example, one or more of a first shim 3508 and a second shim 3510 can be added between the first plate 3502 and the second plate 3504. By adding one or more of the first shim 3508 and the second shim 3510, the midstock 2842 can be adjusted vertically (translation), and the pitch and roll of the midstock 2842 can be adjusted.

[0180] The pads 3500 can also include over-sized bores to further adjust the midstock 2842. For example, the first plate 3502 can include a first bore 3512 and the 3504 can include a second bore 3514. The pads 3500 can also include an adjustment fastener 3516. Because the lower bore 3514 in the second plate can be threaded, this allows adjustment to the midstock 2842 horizontally and in yaw can be achieved by rotating the midstock 2842 in one direction (e.g., clockwise) or another (e.g., counterclockwise).

[0181] By having three plates, the apparatus can be aligned to the machine. One advantage of three plates is that all the alignment can take place between the top andmiddle. Other fasteners (shown in FIG. 36) can then be used to bolt them together. Thus, the entirety of the machine 2802 excluding the bottom plate / pad can be removed. Then, if replaced on the machine (either after use of a module, or maintenance, etc.), dowels and the shims can act together to precision align the midstock 2842 to the rest of the machine with much less or no work of aligning.

[0182] FIG. 37 illustrates an isometric cross-sectional view of an extrusion machine 3700. The extrusion machine 3700 can be similar to any of the machines discussed above such as the shear-assisted extrusion system 900 or the shear-assisted extrusion system 2800.

[0183] The extrusion machine 3700 can include an endstock 3740, a midstock 3742, and a tailstock 3744, which can be similar to the endstock 2840, the midstock 2842, and the tailstock 2844, respectively. FIG. 37 shows that the extrusion machine 3700 can also include motors 3746 and 3748 configured to directly drive the midstock 3742. While two motors 3746 and 3748 are shown, there could be 1, 2, 3, 4, 5, 6, or the like motors, though a symmetric placement around the spindle is preferable. FIG. 37 also shows that the extrusion machine 3700 can include a motor 3750 configured to directly drive the tailstock 3744. In this way, the extrusion machine 3700 can be configured to be driven at the ram and at the container. Such a configuration can be used when modifying an existing or traditional direct extrusion machine to be a shear- assisted extrusion machine or system. If the stem and liner are rotationally interlocked at some point, then the motor 3750 for the tailstock 3744 can be much smaller than the motor(s) 3746, 3748, for the midstock 3742.

[0184] FIG. 38 illustrates a block diagram of an example machine 3800 upon which any one or more of the techniques (e.g., methodologies) discussed herein may perform. Examples, as described herein, may include, or may operate by, logic or a number of components, or mechanisms in the machine 3800. Circuitry (e.g., processing circuitry) is a collection of circuits implemented in tangible entities of the machine 3800 that include hardware (e.g., simple circuits, gates, logic, etc.). Circuitry membership may be flexible over time. Circuitries include members that may, alone or in combination, perform specified operations when operating. In an example, hardware of the circuitry may be immutably designed to carry out a specific operation (e.g., hardwired). In an example, the hardware of the circuitry may include variably connected physical components (e.g., execution units, transistors, simple circuits, etc.) including a machine readable medium physically modified (e.g., magnetically,electrically, moveable placement of invariant massed particles, etc.) to encode instructions of the specific operation. In connecting the physical components, the underlying electrical properties of a hardware constituent are changed, for example, from an insulator to a conductor or vice versa. The instructions enable embedded hardware (e.g., the execution units or a loading mechanism) to create members of the circuitry in hardware via the variable connections to carry out portions of the specific operation when in operation. Accordingly, in an example, the machine readable medium elements are part of the circuitry or are communicatively coupled to the other components of the circuitry when the device is operating. In an example, any of the physical components may be used in more than one member of more than one circuitry. For example, under operation, execution units may be used in a first circuit of a first circuitry at one point in time and reused by a second circuit in the first circuitry, or by a third circuit in a second circuitry at a different time. Additional examples of these components with respect to the machine 3800 follow.

[0185] In alternative embodiments, the machine 3800 may operate as a standalone device or may be connected (e.g., networked) to other machines. In a networked deployment, the machine 3800 may operate in the capacity of a server machine, a client machine, or both in server-client network environments. In an example, the machine 3800 may act as a peer machine in peer-to-peer (P2P) (or other distributed) network environment. The machine 3800 may be a personal computer (PC), a tablet PC, a set-top box (STB), a personal digital assistant (PDA), a mobile telephone, a web appliance, a network router, switch or bridge, or any machine capable of executing instructions (sequential or otherwise) that specify actions to be taken by that machine. Further, while only a single machine is illustrated, the term “machine” shall also be taken to include any collection of machines that individually or jointly execute a set (or multiple sets) of instructions to perform any one or more of the methodologies discussed herein, such as cloud computing, software as a service (SaaS), other computer cluster configurations.

[0186] The machine (e.g., computer system) 3800 may include a hardware processor 3802 (e.g., a central processing unit (CPU), a graphics processing unit (GPU), a hardware processor core, or any combination thereof), a main memory 3804, a static memory (e.g., memory or storage for firmware, microcode, a basic-input- output (BIOS), unified extensible firmware interface (UEFI), etc.) 3806, and mass storage 3808 (e.g., hard drive, tape drive, flash storage, or other block devices) someor all of which may communicate with each other via an interlink (e.g., bus) 3830. The machine 3800 may further include a display unit 3810, an alphanumeric input device 3812 (e.g., a keyboard), and a user interface (UI) navigation device 3814 (e.g., a mouse). In an example, the display unit 3810, input device 3812 and UI navigation device 3814 may be a touch screen display. The machine 3800 may additionally include a storage device (e.g., drive unit) 3808, a signal generation device 3818 (e.g., a speaker), a network interface device 3820, and one or more sensors 3816, such as a global positioning system (GPS) sensor, compass, accelerometer, or other sensor. The machine 3800 may include an output controller 3828, such as a serial (e.g., universal serial bus (USB), parallel, or other wired or wireless (e.g., infrared (IR), near field communication (NFC), etc.) connection to communicate or control one or more peripheral devices (e.g., a printer, card reader, etc.).

[0187] Registers of the processor 3802, the main memory 3804, the static memory 3806, or the mass storage 3808 may be, or include, a machine readable medium 3822 on which is stored one or more sets of data structures or instructions 3824 (e.g., software) embodying or utilized by any one or more of the techniques or functions described herein. The instructions 3824 may also reside, completely or at least partially, within any of registers of the processor 3802, the main memory 3804, the static memory 3806, or the mass storage 3808 during execution thereof by the machine 3800. In an example, one or any combination of the hardware processor 3802, the main memory 3804, the static memory 3806, or the mass storage 3808 may constitute the machine readable media 3822. While the machine readable medium 3822 is illustrated as a single medium, the term "machine readable medium" may include a single medium or multiple media (e.g., a centralized or distributed database, or associated caches and servers) configured to store the one or more instructions 3824.

[0188] The term “machine readable medium” may include any medium that is capable of storing, encoding, or carrying instructions for execution by the machine 3800 and that cause the machine 3800 to perform any one or more of the techniques of the present disclosure, or that is capable of storing, encoding or carrying data structures used by or associated with such instructions. Non-limiting machine readable medium examples may include solid-state memories, optical media, magnetic media, and signals (e.g., radio frequency signals, other photon based signals, sound signals, etc.). In an example, a non-transitory machine readable mediumcomprises a machine readable medium with a plurality of particles having invariant (e.g., rest) mass, and thus are compositions of matter. Accordingly, non-transitory machine-readable media are machine readable media that do not include transitory propagating signals. Specific examples of non-transitory machine readable media may include: non-volatile memory, such as semiconductor memory devices (e.g., Electrically Programmable Read-Only Memory (EPROM), Electrically Erasable Programmable Read-Only Memory (EEPROM)) and flash memory devices; magnetic disks, such as internal hard disks and removable disks; magneto-optical disks; and CD-ROM and DVD-ROM disks.

[0189] The instructions 3824 may be further transmitted or received over a communications network 3826 using a transmission medium via the network interface device 3820 utilizing any one of a number of transfer protocols (e.g., frame relay, internet protocol (IP), transmission control protocol (TCP), user datagram protocol (UDP), hypertext transfer protocol (HTTP), etc.). Example communication networks may include a local area network (LAN), a wide area network (WAN), a packet data network (e.g., the Internet), mobile telephone networks (e.g., cellular networks), Plain Old Telephone (POTS) networks, and wireless data networks (e.g., Institute of Electrical and Electronics Engineers (IEEE) 802.11 family of standards known as WiFi®, IEEE 802.16 family of standards known as WiMax®), IEEE 802.15.4 family of standards, peer-to-peer (P2P) networks, among others. In an example, the network interface device 3820 may include one or more physical jacks (e.g., Ethernet, coaxial, or phonejacks) or one or more antennas to connect to the communications network 3826. In an example, the network interface device 3820 may include a plurality of antennas to wirelessly communicate using at least one of single-input multiple-output (SIMO), multiple-input multiple-output (MIMO), or multiple-input single-output (MISO) techniques. The term “transmission medium” shall be taken to include any intangible medium that is capable of storing, encoding or carrying instructions for execution by the machine 3800, and includes digital or analog communications signals or other intangible medium to facilitate communication of such software. A transmission medium is a machine readable medium.NOTES AND EXAMPLES

[0190] 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.

[0191] Example l is a system for performing shear-assisted extrusion, the system comprising: a die tool including a face configured to engage and plasticize a portion of feedstock material engaged with the face, the die tool defining one or more openings to receive plasticized feedstock material therethrough; a headstock secured to the die tool, the headstock and the die tool together rotatable about a central axis to generate a rotation-induced shear force between feedstock material and the die tool to extrude the feedstock material through the one or more openings of the die tool, the headstock and the die tool axially fixed along the central axis; a midstock configured to support the feedstock material at least partially therein, the midstock configured to translate along the central axis, and the midstock configured to resist rotation; and a tailstock configured to translate along the central axis relative to the headstock and the headstock to generate an axial extrusion force between the feedstock material and the die tool.

[0192] In Example 2, the subject matter of Example 1 optionally includes a ram connected to the tailstock, the ram translatable with the tailstock relative to the headstock and the midstock to extend at least partially into the midstock to engage the feedstock material to generate the axial extrusion force.

[0193] In Example 3, the subject matter of Example 2 optionally includes a container connected to the midstock and configured to support the feedstock material at least partially therein.

[0194] In Example 4, the subject matter of Example 3 optionally includes a liner connected to an inner surface of the container, the liner configured directly engage and support the feedstock material at least partially therein.

[0195] In Example 5, the subject matter of any one or more of Examples 1-4 optionally include a plurality of rails and bearings connected to the headstock, the midstock, and the tailstock, the tailstock translatable along the plurality of rails with respect to the headstock and the midstock.

[0196] In Example 6, the subject matter of Example 5 optionally includes a lock movable between a locked position and an unlocked position, the lock engaged with the midstock in the locked position to restrict axial movement of the midstock, andthe midstock movable along the plurality of rails relative to the headstock and the tailstock when the lock is in the unlocked position.

[0197] In Example 7, the subject matter of Example 6 optionally includes wherein the midstock is manually translatable along the plurality of rails when the lock is in the unlocked position.

[0198] In Example 8, the subject matter of any one or more of Examples 5-7 optionally include a spindle connected to the headstock and to the die tool, the spindle and the die tool rotatable about the central axis relative to the headstock, the midstock, and the tailstock; and a spindle motor connected to the spindle and operable to drive the spindle to rotate.

[0199] In Example 9, the subject matter of Example 8 optionally includes a plurality of shafts connected to the headstock and the tailstock; and one or more actuators connected to the headstock or the tailstock, the one or more actuators operable to drive the plurality of shafts to translate the tailstock along the plurality of rails.

[0200] In Example 10, the subject matter of Example 9 optionally includes a plurality of midstock shafts connected to the midstock and the tailstock; and one or more actuators connected to the midstock, the one or more actuators operable to drive the plurality of shafts to translate the tailstock along the plurality of rails.

[0201] In Example 11, the subject matter of any one or more of Examples 6-10 optionally include a control system configured to operate the headstock, the tailstock, and the lock.

[0202] Example 12 is a system for performing shear-assisted extrusion, the system comprising: an endstock fixed with respect to a central axis; a die tool connected to the endstock, the die tool including a face configured to engage and plasticize a portion of feedstock material engaged with the face, the die tool defining one or more openings to receive plasticized feedstock material therethrough; a headstock connected to the endstock; a headstock spindle connected to the headstock and configured to support the feedstock material at least partially therein, the headstock spindle rotatable about the central axis to generate a rotation-induced shear force between the feedstock material and the die tool to extrude the feedstock material through the opening of the die tool; a tailstock connected to the endstock and configured to translate along the central axis relative to the endstock and the headstock to generate an axial extrusion force between the feedstock material and thedie tool; and a tailstock spindle connected to the tailstock, the tailstock spindle rotatable about the central axis to generate a rotation-induced shear force between the feedstock material and the die tool to extrude the feedstock material through the opening of the die tool.

[0203] In Example 13, the subject matter of Example 12 optionally includes a ram connected to the tailstock, the ram translatable with the tailstock relative to the headstock and the endstock to extend at least partially into the headstock to engage the feedstock material to generate the axial extrusion force.

[0204] In Example 14, the subject matter of Example 13 optionally includes a headstock spindle motor connected to the headstock spindle and operable to drive the headstock spindle to rotate; and a tailstock spindle motor connected to the tailstock spindle and operable to drive the tailstock spindle to rotate.

[0205] In Example 15, the subject matter of Example 14 optionally includes a controller connected to the headstock spindle motor and the tailstock spindle motor, the controller configured to operate the headstock spindle motor and the tailstock spindle motor based on a rotational speed of the feedstock material.

[0206] In Example 16, the subject matter of Example 15 optionally includes wherein the controller is configured to balance a total torque delivered by the headstock spindle motor and the tailstock spindle motor based on a total torque delivered by the headstock spindle motor and the tailstock spindle motor.

[0207] In Example 17, the subject matter of any one or more of Examples 12-16 optionally include a plurality of rails connected to the headstock, the endstock, and the tailstock, the tailstock translatable along the plurality of rails with respect to the headstock and the endstock.

[0208] In Example 18, the subject matter of Example 17 optionally includes a plurality of shafts connected to the endstock and the tailstock; and one or more actuators connected to the endstock or the tailstock, the one or more actuators operable to drive the plurality of shafts to translate the tailstock along the plurality of rails with respect to the headstock and the endstock.

[0209] In Example 19, the subject matter of Example 18 optionally includes a plurality of headstock shafts connected to the endstock and the headstock; and one or more actuators connected to the endstock or the headstock, the one or more actuators operable to drive the plurality of headstock shafts to translate the headstock along the plurality of rails with respect to the tailstock and the endstock.

[0210] In Example 20, the subject matter of Example 19 optionally includes wherein the headstock is configured to translate along the central axis with respect to the endstock and the tailstock.

[0211] In Example 21, the subject matter of Example 20 optionally includes a plurality of shafts connected to the endstock and the tailstock; and one or more actuators connected to the endstock or the tailstock, the one or more actuators operable to drive the plurality of shafts to translate the tailstock along the plurality of rails.

[0212] In Example 22, the subject matter of Example 21 optionally includes a plurality of headstock shafts connected to the headstock and the endstock; and one or more actuators connected to the endstock or the headstock, the one or more actuators operable to drive the plurality of headstock shafts to translate the headstock along the plurality of rails.

[0213] Example 23 is a system for shear-assisted extrusion, the system comprising: a die tool configured to engage feedstock material, the die tool defining one or more opening to receive the feedstock material therethrough; a container configured to support the feedstock material at least partially therein, the container configured to rotate during extruding, and the die tool or a ram configured to translate to generate an axial extrusion force to generate a rotation-induced shear force at an interface between the die tool and the feedstock material to form extrudate through the opening; and a liner connected to an inner surface of the container, the liner configured to engage and support the feedstock material at least partially therein, the liner comprising: a first end portion configured to receive the die tool at least partially therein; and a second end portion opposite the first end portion, the second end portion configured to engage with the container to cause the liner to rotate with the container and the feedstock material to generate the rotation-induced shear force.

[0214] In Example 24, the subject matter of Example 23 optionally includes wherein the liner includes a plurality of recesses extending axially into the liner from an end surface of the second end portion, the plurality of recesses configured to mate with a base of the container to allow the container to either directly or indirectly drive the liner to rotate together with the container.

[0215] In Example 25, the subject matter of Example 24 optionally includes a plurality of keys secured to the base of the container, the plurality of keys at leastpartially insertable into respective ones of the plurality of recesses to allow the container to drive the liner to rotate together with the container.

[0216] In Example 26, the subject matter of Example 25 optionally includes wherein the container includes a jacket including a first container end portion and a second container end portion opposite the first container end portion, the first container end portion configured to receive the die tool at least partially therein, and the second container end portion configured to engage with the base of the container.

[0217] In Example 27, the subject matter of Example 26 optionally includes wherein the jacket includes a plurality of container recesses extending axially into the container from the second container end portion, the plurality of recesses configured to mate with respective ones of the plurality of keys to allow the base to drive the container to rotate together with the liner.

[0218] In Example 28, the subject matter of Example 27 optionally includes wherein each of the plurality of container recesses is in radial alignment with one of the plurality of recesses of the liner.

[0219] In Example 29, the subject matter of any one or more of Examples 25-28 optionally include a spacer comprising a first end portion and a second end portion opposite the first end portion, the spacer comprising: a plurality of bosses extending from the first end portion, the plurality of bosses insertable into the plurality of recesses of the liner to allow transmission of rotation from the spacer to the liner; and a plurality of spacer recesses extending into the second end portion, the plurality of keys at least partially insertable into respective ones of the plurality of spacer recesses to allow the container to drive the spacer and the liner to rotate together with the container.

[0220] In Example 30, the subject matter of Example 29 optionally includes wherein each of the plurality of bosses are circumferentially offset from each of the plurality of spacer recesses.

[0221] In Example 31, the subject matter of any one or more of Examples 25-30 optionally include wherein each of the plurality of keys are releasably securable to the base of the container.

[0222] In Example 32, the subject matter of any one or more of Examples 23-31 optionally include wherein the ram is insertable into the container and the liner to directly or indirectly engage with the feedstock material, the ram configured to rotate relative to the die tool to establish the rotation-induced shear force, and the ramconfigured to axially translate relative to the container, the liner, the die tool, and the feedstock material during extruding to, together with the container and the liner, generate the axial extrusion force.

[0223] In Example 33, the subject matter of any one or more of Examples 23-32 optionally include wherein the die tool is configured to maintain a rotational position during extruding.

[0224] Example 34 is a system for shear-assisted extrusion, the system comprising: a die tool configured to engage feedstock material, the die tool defining an opening to receive the feedstock material therethrough; a container configured to support the feedstock material at least partially therein, the container or the die tool configured to rotate during extruding, and the die tool, a ram, or the container configured to translate to generate an axial extrusion force to generate a rotation-induced shear force at an interface between the die tool and the feedstock material to form extrudate through the opening; and a liner connected to an inner surface of the container, the liner configured to engage and support the feedstock material at least partially therein, the liner comprising: a first end portion configured to receive the die tool at least partially therein; and a second end portion opposite the first end portion, the second end portion including a torque interface configured to engage with the container or a spindle to rotationally fix the liner with respect to a rotational orientation of the container and the feedstock material during application of the rotation-induced shear force.

[0225] In Example 35, the subject matter of Example 34 optionally includes wherein the torque interface includes a plurality of recesses extending axially into the liner from an end surface of the second end portion, the plurality of recesses configured to mate with a base of the container to allow the container to drive the liner to rotate together with the container.

[0226] In Example 36, the subject matter of Example 35 optionally includes a plurality of keys secured to the base of the container, the plurality of keys at least partially insertable into respective ones of the plurality of recesses to allow the container to drive the liner to rotate together with the container.

[0227] In Example 37, the subject matter of Example 36 optionally includes wherein the container includes a jacket including a first container end portion and a second container end portion opposite the first container end portion, the firstcontainer end portion configured to receive the die tool at least partially therein, and the second container end portion configured to engage with the base of the container.

[0228] In Example 38, the subject matter of any one or more of Examples 36-37 optionally include a spacer comprising a first end portion and a second end portion opposite the first end portion, the spacer comprising: a plurality of bosses extending from the first end portion, the plurality of bosses insertable into the plurality of recesses of the liner to allow transmission of rotation from the spacer to the liner; and a plurality of spacer recesses extending into the second end portion, the plurality of keys at least partially insertable into respective ones of the plurality of spacer recesses to allow the container to drive the spacer and the liner to rotate together with the container.

[0229] In Example 39, the subject matter of Example 38 optionally includes wherein each of the plurality of bosses are circumferentially offset from each of the plurality of spacer recesses.

[0230] In Example 40, the subject matter of any one or more of Examples 36-39 optionally include wherein each of the plurality of keys are releasably securable to the base of the container.

[0231] In Example 41, the subject matter of any one or more of Examples 34-40 optionally include wherein the ram is insertable into the container and the liner to directly or indirectly engage with the feedstock material, the ram configured to rotate relative to the die tool to establish the rotation-induced shear force, and the ram configured to axially translate relative to the container, the liner, the die tool, and the feedstock material during extruding to, together with the container and the liner, generate the axial extrusion force.

[0232] In Example 42, the subject matter of any one or more of Examples 34-41 optionally include wherein the die tool is configured to rotate relative to the container and the liner during extruding.

[0233] Example 43 is a system for shear-assisted extrusion, the system comprising: a die tool configured to engage feedstock material, the die tool including an opening to receive the feedstock material therethrough; a container configured to support the feedstock material at least partially therein, the container configured to rotate to generate a rotation-induced shear force at an interface between the die tool and the feedstock material; and a ram configured to interlock with the container to rotate withthe container, and the ram configured to translate to generate an axial extrusion force to, together with the rotation-induced shear force, form extrudate through the opening.

[0234] In Example 44, the subject matter of Example 43 optionally includes wherein the die tool is configured to be fixed relative to the container during extruding.

[0235] In Example 45, the subject matter of any one or more of Examples 43-44 optionally include wherein the ram is configured to be driven and to transfer rotation to the container.

[0236] In Example 46, the subject matter of any one or more of Examples 43-45 optionally include wherein the ram is configured to translate relative to the container and relative to the die tool during extruding.

[0237] In Example 47, the subject matter of Example 46 optionally includes wherein the ram includes a stem movable between an engaged position and a disengaged position, the stem coupled to the container to rotate therewith in the engaged position, and the stem uncoupled from the container in the disengaged position.

[0238] In Example 48, the subject matter of Example 47 optionally includes wherein the ram includes a bearing translatable with the stem, the bearing engageable with the container when the stem is in the engaged position to transfer rotational forces between the stem and the container during rotation of the stem and the container.

[0239] In Example 49, the subject matter of any one or more of Examples 47-48 optionally include a liner connected to an inner portion of the container, the liner configured to support the feedstock material at least partially therein; and a thrust coupler securable to the liner and engageable with the container to limit relative movement of the liner with respect to the container during extruding.

[0240] In Example 50, the subject matter of Example 49 optionally includes wherein the thrust coupler is threadably releasable from the liner to allow the liner to be removed from the container.

[0241] In Example 51, the subject matter of Example 50 optionally includes a torsion coupler securable to one or more of the thrust coupler and the container and engageable with the liner to limit relative rotation of the liner and the container during extruding.

[0242] In Example 52, the subject matter of any one or more of Examples 43-51 optionally include a cooling sleeve connected to a housing of the container such that the container is rotatable with respect to the cooling sleeve, the cooling sleeve configured to receive cooling fluid therein or therethrough to cool the container or the feedstock material during extruding.

[0243] In Example 53, the subject matter of any one or more of Examples 43-52 optionally include a die holder configured to support the die tool during extruding; and a plurality of standoffs connected to the die holder.

[0244] In Example 54, the subject matter of Example 53 optionally includes wherein the plurality of standoffs are engageable with a housing of the container to transfer reaction forces caused by the axial extrusion force between the die holder and the container.

[0245] In Example 55, the subject matter of Example 54 optionally includes wherein each of the plurality of standoffs includes a first portion couplable to a second portion, the second portion releasable from the first portion to adjust a distance between the container and the die holder when the housing of the container engages the plurality of standoffs.

[0246] In Example 56, the subject matter of any one or more of Examples 53-55 optionally include a strain gauge connected one or more of the plurality of standoffs.

[0247] Example 57 is a system for shear-assisted extrusion, the system comprising: a die tool configured to engage feedstock material, the die tool including an opening to receive the feedstock material therethrough; a container configured to support the feedstock material at least partially therein, the container configured to rotate to generate a rotation-induced shear force at an interface between the die tool and the feedstock material; a ram configured to interlock with the container to rotate with the container, and the ram configured translate to generate an axial extrusion force to, together with the rotation-induced shear force, form extrudate through the opening; a liner connected to an inner portion of the container, the liner configured to support the feedstock material at least partially therein; and a thrust coupler threadably securable to the liner and engageable with the container to limit relative movement of the liner with respect to the container during extruding.

[0248] In Example 58, the subject matter of Example 57 optionally includes wherein the ram includes a stem movable between an engaged position and adisengaged position, the stem coupled to the liner to rotate therewith in the engaged position, and the stem uncoupled from the liner in the disengaged position.

[0249] In Example 59, the subject matter of Example 58 optionally includes wherein the ram includes a bearing translatable with the stem, the bearing engageable with the liner when the stem is in the engaged position to transfer rotational forces between the stem and the container during rotation of the stem and the container.

[0250] In Example 60, the subject matter of Example 59 optionally includes wherein the thrust coupler is removable to allow the liner to be removed from the container.

[0251] In Example 61, the subject matter of Example 60 optionally includes a torsion coupler securable to one or more of the thrust coupler and the container and engageable with the liner to limit relative rotation of the liner and the container during extruding.

[0252] In Example 62, the apparatuses or method of any one or any combination of Examples 1 - 61 can optionally be configured such that all elements or options recited are available to use or select from.

[0253] 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.

[0254] 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.

[0255] 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.

[0256] 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 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.

Claims

CLAIMS:

1. A system for performing shear-assisted extrusion, the system comprising: a die tool including a face configured to engage and plasticize a portion of feedstock material engaged with the face, the die tool defining one or more openings to receive plasticized feedstock material therethrough; a headstock secured to the die tool, the headstock and the die tool together rotatable about a central axis to generate a rotation-induced shear force between feedstock material and the die tool to extrude the feedstock material through the one or more openings of the die tool, the headstock and the die tool axially fixed along the central axis; a midstock configured to support the feedstock material at least partially therein, the midstock configured to translate along the central axis, and the midstock configured to resist rotation; and a tailstock configured to translate along the central axis relative to the headstock and the headstock to generate an axial extrusion force between the feedstock material and the die tool.

2. The system of claim 1, comprising: a ram connected to the tailstock, the ram translatable with the tailstock relative to the headstock and the midstock to extend at least partially into the midstock to engage the feedstock material to generate the axial extrusion force.

3. The system of claim 2, comprising: a container connected to the midstock and configured to support the feedstock material at least partially therein.

4. The system of claim 3, comprising: a liner connected to an inner surface of the container, the liner configured directly engage and support the feedstock material at least partially therein.

5. The system of claim 1, comprising:a plurality of rails and bearings connected to the headstock, the midstock, and the tailstock, the tailstock translatable along the plurality of rails with respect to the headstock and the midstock.

6. The system of claim 5, comprising: a lock movable between a locked position and an unlocked position, the lock engaged with the midstock in the locked position to restrict axial movement of the midstock, and the midstock movable along the plurality of rails relative to the headstock and the tailstock when the lock is in the unlocked position.

7. The system of claim 6, wherein the midstock is manually translatable along the plurality of rails when the lock is in the unlocked position.

8. The system of claim 5, comprising: a spindle connected to the headstock and to the die tool, the spindle and the die tool rotatable about the central axis relative to the headstock, the midstock, and the tailstock; and a spindle motor connected to the spindle and operable to drive the spindle to rotate.

9. The system of claim 8, comprising: a plurality of shafts connected to the headstock and the tailstock; and one or more actuators connected to the headstock or the tailstock, the one or more actuators operable to drive the plurality of shafts to translate the tailstock along the plurality of rails.

10. The system of claim 9, comprising: a plurality of midstock shafts connected to the midstock and the tailstock; and one or more actuators connected to the midstock, the one or more actuators operable to drive the plurality of shafts to translate the tailstock along the plurality of rails.

11. The system of claim 6, comprising:a control system configured to operate the headstock, the tailstock, and the lock.

12. A system for performing shear-assisted extrusion, the system comprising: an endstock fixed with respect to a central axis; a die tool connected to the endstock, the die tool including a face configured to engage and plasticize a portion of feedstock material engaged with the face, the die tool defining one or more openings to receive plasticized feedstock material therethrough; a headstock connected to the endstock; a headstock spindle connected to the headstock and configured to support the feedstock material at least partially therein, the headstock spindle rotatable about the central axis to generate a rotation-induced shear force between the feedstock material and the die tool to extrude the feedstock material through the opening of the die tool; a tailstock connected to the endstock and configured to translate along the central axis relative to the endstock and the headstock to generate an axial extrusion force between the feedstock material and the die tool; and a tailstock spindle connected to the tailstock, the tailstock spindle rotatable about the central axis to generate a rotation-induced shear force between the feedstock material and the die tool to extrude the feedstock material through the opening of the die tool.

13. The system of claim 12, comprising: a ram connected to the tailstock, the ram translatable with the tailstock relative to the headstock and the endstock to extend at least partially into the headstock to engage the feedstock material to generate the axial extrusion force.

14. The system of claim 13, comprising: a headstock spindle motor connected to the headstock spindle and operable to drive the headstock spindle to rotate; anda tailstock spindle motor connected to the tailstock spindle and operable to drive the tailstock spindle to rotate.

15. The system of claim 14, comprising: a controller connected to the headstock spindle motor and the tailstock spindle motor, the controller configured to operate the headstock spindle motor and the tailstock spindle motor based on a rotational speed of the feedstock material.

16. The system of claim 15, wherein the controller is configured to balance a total torque delivered by the headstock spindle motor and the tailstock spindle motor based on a total torque delivered by the headstock spindle motor and the tailstock spindle motor.

17. The system of claim 12, comprising: a plurality of rails connected to the headstock, the endstock, and the tailstock, the tailstock translatable along the plurality of rails with respect to the headstock and the endstock.

18. The system of claim 17, comprising: a plurality of shafts connected to the endstock and the tailstock; and one or more actuators connected to the endstock or the tailstock, the one or more actuators operable to drive the plurality of shafts to translate the tailstock along the plurality of rails with respect to the headstock and the endstock.

19. The system of claim 18, comprising: a plurality of headstock shafts connected to the endstock and the headstock; and one or more actuators connected to the endstock or the headstock, the one or more actuators operable to drive the plurality of headstock shafts to translate the headstock along the plurality of rails with respect to the tailstock and the endstock.

20. The system of claim 19, wherein the headstock is configured to translate along the central axis with respect to the endstock and the tailstock.

21. The system of claim 20, comprising: a plurality of shafts connected to the endstock and the tailstock; and one or more actuators connected to the endstock or the tailstock, the one or more actuators operable to drive the plurality of shafts to translate the tailstock along the plurality of rails.

22. The system of claim 21, comprising: a plurality of headstock shafts connected to the headstock and the endstock; and one or more actuators connected to the endstock or the headstock, the one or more actuators operable to drive the plurality of headstock shafts to translate the headstock along the plurality of rails.

23. A system for shear-assisted extrusion, the system comprising: a die tool configured to engage feedstock material, the die tool defining one or more opening to receive the feedstock material therethrough; a container configured to support the feedstock material at least partially therein, the container configured to rotate during extruding, and the die tool or a ram configured to translate to generate an axial extrusion force to generate a rotation-induced shear force at an interface between the die tool and the feedstock material to form extrudate through the opening; and a liner connected to an inner surface of the container, the liner configured to engage and support the feedstock material at least partially therein, the liner comprising: a first end portion configured to receive the die tool at least partially therein; and a second end portion opposite the first end portion, the second end portion configured to engage with the container to cause the liner to rotate with the container and the feedstock material to generate the rotation-induced shear force.

24. The system of claim 23, wherein the liner includes a plurality of recesses extending axially into the liner from an end surface of the second end portion, the plurality of recesses configured to mate with a base of the container to allow the container to drive the liner to rotate together with the container.

25. The system of claim 24, further comprising: a plurality of keys secured to the base of the container, the plurality of keys at least partially insertable into respective ones of the plurality of recesses to allow the container to drive the liner to rotate together with the container.

26. The system of claim 25, wherein the container includes a jacket including a first container end portion and a second container end portion opposite the first container end portion, the first container end portion configured to receive the die tool at least partially therein, and the second container end portion configured to engage with the base of the container.

27. The system of claim 26, wherein the jacket includes a plurality of container recesses extending axially into the container from the second container end portion, the plurality of recesses configured to mate with respective ones of the plurality of keys to allow the base to drive the container to rotate together with the liner.

28. The system of claim 27, wherein each of the plurality of container recesses is in radial alignment with one of the plurality of recesses of the liner.

29. The system of claim 25, comprising: a spacer comprising a first end portion and a second end portion opposite the first end portion, the spacer comprising: a plurality of bosses extending from the first end portion, the plurality of bosses insertable into the plurality of recesses of the liner to allow transmission of rotation from the spacer to the liner; anda plurality of spacer recesses extending into the second end portion, the plurality of keys at least partially insertable into respective ones of the plurality of spacer recesses to allow the container to drive the spacer and the liner to rotate together with the container.

30. The system of claim 29, wherein each of the plurality of bosses are circumferentially offset from each of the plurality of spacer recesses.

31. The system of claim 25, wherein each of the plurality of keys are releasably securable to the base of the container.

32. The system of claim 23, wherein the ram is insertable into the container and the liner to directly or indirectly engage with the feedstock material, the ram configured to rotate relative to the die tool to establish the rotation-induced shear force, and the ram configured to axially translate relative to the container, the liner, the die tool, and the feedstock material during extruding to, together with the container and the liner, generate the axial extrusion force.

33. The system of claim 23, wherein the die tool is configured to maintain a rotational position during extruding.

34. A system for shear-assisted extrusion, the system comprising: a die tool configured to engage feedstock material, the die tool defining an opening to receive the feedstock material therethrough; a container configured to support the feedstock material at least partially therein, the container or the die tool configured to rotate during extruding, and the die tool, a ram, or the container configured to translate to generate an axial extrusion force to generate a rotation- induced shear force at an interface between the die tool and the feedstock material to form extrudate through the opening; and a liner connected to an inner surface of the container, the liner configured engage and support the feedstock material at least partially therein, the liner comprising:a first end portion configured to receive the die tool at least partially therein; and a second end portion opposite the first end portion, the second end portion including a torque interface configured to engage with the container or a spindle to rotationally fix the liner with respect to a rotational orientation of the container and the feedstock material during application of the rotation-induced shear force.

35. The system of claim 34, wherein the torque interface includes a plurality of recesses extending axially into the liner from an end surface of the second end portion, the plurality of recesses configured to mate with a base of the container to allow the container to drive the liner to rotate together with the container.

36. The system of claim 35, further comprising: a plurality of keys secured to the base of the container, the plurality of keys at least partially insertable into respective ones of the plurality of recesses to allow the container to drive the liner to rotate together with the container.

37. The system of claim 36, wherein the container includes a jacket including a first container end portion and a second container end portion opposite the first container end portion, the first container end portion configured to receive the die tool at least partially therein, and the second container end portion configured to engage with the base of the container.

38. The system of claim 36, comprising: a spacer comprising a first end portion and a second end portion opposite the first end portion, the spacer comprising: a plurality of bosses extending from the first end portion, the plurality of bosses insertable into the plurality of recesses of the liner to allow transmission of rotation from the spacer to the liner; anda plurality of spacer recesses extending into the second end portion, the plurality of keys at least partially insertable into respective ones of the plurality of spacer recesses to allow the container to drive the spacer and the liner to rotate together with the container.

39. The system of claim 38, wherein each of the plurality of bosses are circumferentially offset from each of the plurality of spacer recesses.

40. The system of claim 36, wherein each of the plurality of keys are releasably securable to the base of the container.

41. The system of claim 34, wherein the ram is insertable into the container and the liner to directly or indirectly engage with the feedstock material, the ram configured to rotate relative to the die tool to establish the rotation-induced shear force, and the ram configured to axially translate relative to the container, the liner, the die tool, and the feedstock material during extruding to, together with the container and the liner, generate the axial extrusion force.

42. The system of claim 34, wherein the die tool is configured to rotate relative to the container and the liner during extruding.

43. A system for shear-assisted extrusion, the system comprising: a die tool configured to engage feedstock material, the die tool including an opening to receive the feedstock material therethrough; a container configured to support the feedstock material at least partially therein, the container configured to rotate to generate a rotation- induced shear force at an interface between the die tool and the feedstock material; and a ram configured to interlock with the container to rotate with the container, and the ram configured to translate to generate an axial extrusion force to, together with the rotation-induced shear force, form extrudate through the opening.

44. The system of claim 43, wherein the die tool is configured to be fixed relative to the container during extruding.

45. The system of claim 43, wherein the ram is configured to be driven and to transfer rotation to the container.

46. The system of claim 43, wherein the ram is configured to translate relative to the container and relative to the die tool during extruding.

47. The system of claim 46, wherein the ram includes a stem movable between an engaged position and a disengaged position, the stem coupled to the container to rotate therewith in the engaged position, and the stem uncoupled from the container in the disengaged position.

48. The system of claim 47, wherein the ram includes a bearing translatable with the stem, the bearing engageable with the container when the stem is in the engaged position to transfer rotational forces between the stem and the container during rotation of the stem and the container.

49. The system of claim 47, comprising: a liner connected to an inner portion of the container, the liner configured to support the feedstock material at least partially therein; and a thrust coupler securable to the liner and engageable with the container to limit relative movement of the liner with respect to the container during extruding.

50. The system of claim 49, wherein the thrust coupler is threadably releasable from the liner to allow the liner to be removed from the container.

51. The system of claim 50, comprising: a torsion coupler securable to one or more of the thrust coupler and the container and engageable with the liner to limit relative rotation of the liner and the container during extruding.

52. The system of claim 43, comprising: a cooling sleeve connected to a housing of the container such that the container is rotatable with respect to the cooling sleeve, the cooling sleeve configured to receive cooling fluid therein or therethrough to cool the container or the feedstock material during extruding.

53. The system of claim 43, comprising: a die holder configured to support the die tool during extruding; and a plurality of standoffs connected to the die holder.

54. The system of claim 53, wherein the plurality of standoffs are engageable with a housing of the container to transfer reaction forces caused by the axial extrusion force between the die holder and the container.

55. The system of claim 54, wherein each of the plurality of standoffs includes a first portion couplable to a second portion, the second portion releasable from the first portion to adjust a distance between the container and the die holder when the housing of the container engages the plurality of standoffs.

56. The system of claim 53, comprising: a strain gauge connected one or more of the plurality of standoffs.

57. A system for shear-assisted extrusion, the system comprising: a die tool configured to engage feedstock material, the die tool including an opening to receive the feedstock material therethrough; a container configured to support the feedstock material at least partially therein, the container configured to rotate to generate a rotation- induced shear force at an interface between the die tool and the feedstock material; a ram configured to interlock with the container to rotate with the container, and the ram configured translate to generate an axial extrusion force to, together with the rotation-induced shear force, form extrudate through the opening;a liner connected to an inner portion of the container, the liner configured to support the feedstock material at least partially therein; and a thrust coupler threadably securable to the liner and engageable with the container to limit relative movement of the liner with respect to the container during extruding.

58. The system of claim 57, wherein the ram includes a stem movable between an engaged position and a disengaged position, the stem coupled to the liner to rotate therewith in the engaged position, and the stem uncoupled from the liner in the disengaged position.

59. The system of claim 58, wherein the ram includes a bearing translatable with the stem, the bearing engageable with the liner when the stem is in the engaged position to transfer rotational forces between the stem and the container during rotation of the stem and the container.

60. The system of claim 59, wherein the thrust coupler is removable to allow the liner to be removed from the container.

61. The system of claim 60, comprising: a torsion coupler securable to one or more of the thrust coupler and the container and engageable with the liner to limit relative rotation of the liner and the container during extruding.

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