Direct shear-assisted extrusion machine

Abstract

A system for performing shear-assisted extrusion or friction extrusion can include a die tool, a rotating assembly, a container, and a ram. The die tool can include a face configured to engage and plasticize a portion of feedstock material engaged with the face. The rotating assembly can include a housing and a spindle connected to the housing and connected to the die tool. The spindle rotatable together with the die tool relative to the housing 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 die tool. The container can support the feedstock material at least partially therein. The container can translate along the central axis between a disengaged configuration and an engaged configuration wherein the container is engaged with the housing to resist rotation of the container relative to the housing.

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 fabrication 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 can be forced to flow through a die aperture. The process is commonly used to form pipes, tubes, structural members 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] FIG. 1 illustrates a cross-sectional view of an extrusion system.

[0006] FIG. 2 illustrates a cross-sectional view of an extrusion system.

[0007] FIG. 3 A illustrates a top isometric view of a porthole die.

[0008] FIG. 3B illustrates a bottom isometric view of a porthole die.

[0009] FIG. 4 illustrates a schematic view of a shear-assisted extrusion system.

[0010] FIG. 5 illustrates an isometric view of a portion of a shear-assisted extrusion system.

[0011] FIG. 6 illustrates a cross-sectional view of a portion of a shear-assisted extrusion system.

[0012] FIG. 7 illustrates a cross-sectional view of a portion of a shear-assisted extrusion system.

[0013] FIG. 8 illustrates a cross-sectional view of a portion of a shear-assisted extrusion system.

[0014] FIG. 9 illustrates a cross-sectional view of a portion of a shear-assisted extrusion system.

[0015] FIG. 10 illustrates a cross-sectional view of a portion of a shear-assisted extrusion system.

[0016] FIG. 11 illustrates a cross-sectional view of a portion of a shear-assisted extrusion system.

[0017] FIG. 12 illustrates an isometric view of a portion of a shear-assisted extrusion system.

[0018] FIG. 13 illustrates a cross-sectional view of a portion of a shear-assisted extrusion system.

[0019] FIG. 14 illustrates a cross-sectional view of a portion of a shear-assisted extrusion system.

[0020] FIG. 15 illustrates a schematic view of a shear-assisted extrusion system.

[0021] FIG. 16 illustrates a schematic view of a method of operating one or more systems.

[0022] FIG. 17 illustrates a block diagram illustrating an example of a machine upon which one or more embodiments may be implemented.DETAILED DESCRIPTION

[0023] In the field of extrusion, there is a need to produce extrudate having complex shapes as efficiently and affordable as possible. Shear Assisted Processing and Extrusion (ShAPE) and friction extrusion (FE) processes have been used to generate superior performing extrudate at a reduced energy usage; however, to date,most of the processes practice an indirect extrusion method, which can may be less scalable for industrial manufacturing.

[0024] The present techniques can help address one or more of the challenges of scaling and commercial adoption of these processes, such as by modifying or retrofitting an existing direct extrusion machine or machines (such as an industrial scale machine) to include a rotating die assembly that allow the direct extrusion machine to be used as a direct extrusion ShAPE or FE machine. For example, the machine can include a headstock (which can be a platten, a die pocket, or the like) including a rotating die tool and can include a tailstock (which can be a ram or stem) that can generate an axial extrusion force. Such a machine can also include a movable midstock (which can be or can include a container), which can be used for machine service and loading of feedstock. This adaptation of direct extrusion ShAPE machine can be relatively more scalable for high-cycle industrial manufacturing purposes.

[0025] The machine can also include a headstock and a midstock that are configured to engaged or interconnect during extrusion operations. The connection between the headstock and the midstock can allow for the spindle of the headstock to rotate with respect to the midstock such that the die tool can rotate relative to the container while the midstock and container are connected to a housing of the headstock. This connection can allow for a torque path to remain between the spindle and the container such that the extrusion machine tie rods do not (or minimally) receive torque from the spindle during ShAPE operations, which can simplify requirements for modifying an existing extrusion machine to perform ShAPE or friction stir operations. In this way, the torque of the shear-assisted extrusion system (or FE system) can be self-contained between the headstock and the container such that torque is not transmitted (or is limited in transmission) to the tie rods or the ram assembly or machine frame. This can help to reduce required modifications, such as reinforcement of structural components, of or to a direct extrusion machine to allow such a direct extrusion machine become a shear-assisted extrusion system.

[0026] Though the headstock, the midstock, and the tailstock 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.

[0027] 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.

[0028] FIG. 1 illustrates a cross-sectional view of an extrusion system 100. FIG. 2 illustrates a cross-sectional view of an extrusion system 100. FIGS. 1 and 2 are discussed together below.

[0029] As shown in FIGS. 1 and 2, a die assembly 110 can include a die tool 111 including a die face 128 that can be thrust against and into a billet material 120 (or vice versa). The die face 128 can include one or more scrolls (e.g., a fluted or spiral topology defining surface contours that direct plasticized material inward as the die face 128 rotates relative to the billet material 120, illustrated further in FIG. 3A), the die face 128 can include other surface features, or it can even be flat. The billet material 120 can be held within a billet holder assembly 112 (or container assembly) that can include a container base 112A and a container sidewall 112B. The scrolls can include various fluted, spiral, or other patterns or styles of topology including constant curvature pitch and non-constant curvature pitch.

[0030] 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. 1 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.

[0031] Flow of the plasticized material can be directed, such as through an extrusion aperture, to another location, such as an internal portion 118 of the die assembly 110. The die face 128 can define a die face orifice 134. 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 134 in the die face 128, the mandrel 116 canform an annular extrusion aperture (e.g., annular extrusion aperture 132) 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 134 in the die face 128. In some examples, the mandrel 116 can be rigidly affixed to the die face 128 is illustrated in FIG. 2.

[0032] The extrusion system 100 of FIGS. 1 and 2 can be similarly configured but can move differently. For example, as shown in FIG. 1, the die assembly 110 (including the die holder 121, the die shank 114, and the die tool 111) 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-induced shear 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 130, 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.

[0033] As shown in FIG. 2, the billet holder assembly 112 (including the container base 112A, the container sidewall 112B, the liner 130, 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 die tool 111) 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.

[0034] The die face 128 can be part of the die tool 111, such as a porthole die. The die tool 111 can include portholes 117. The die tool 111 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 die tool 111. The plasticized billet material extruded through the holes of the die tool 11 lean be extruded to surround the mandrel 116 behind the die tool 11 land 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 extrudedstructure (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 134 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.

[0035] FIGS. 3 A and 3B illustrate, by way of example and not limitation, respective top and bottom isometric views of a porthole die with a modified scroll face and mandrel. FIG. 3 A illustrates a top isometric view of the die tool 111 showing the modified scroll face and FIG. 3B illustrates a bottom isometric view of the die tool 111 showing the portholes and a mandrel. Grooves 113 and 115 can extend into the die face 128 of the die tool 111 surface 124, extending into the die from an outer surface but may or may not be needed depending on the alloy and process parameters. The Grooves 113 and 115 can help direct plasticized billet material to more effectively generate heat and help material flow toward the portholes 117. The threaded holes 123 can be used to attach the die face to the die shank.

[0036] 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 tool 111 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.

[0037] In this illustrative example, one groove 113 can feed material radially outward toward each aperture port 117 for a total of four outward flowing grooves. The outer grooves 115 on the die face 128 can feed material radially inward toward the aperture port 117. In this illustrative example, two grooves can feed material radially inward toward each aperture port 117 for a total of eight inward feeding grooves 115. In addition to these two sets of grooves, the die tool 111 can include a perimeter scrolled groove 119 located radially or laterally outward on an outerperimeter surface 126 of the die tool 111, 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 130 (or, in the absence of a liner, the container sidewall 112B) and die assembly 110 during extrusion.

[0038] In FIG. 3B, the die tool 111 shows a series of full penetration of portholes 117. In use, streams of plasticized billet material can be directed by the inward 115 and outward 113 grooves described above can pass through these portholes 117 and can then be recombined and flow around a mandrel 116 to create a desired cross section. In this way, the grooves 113, 115, and 119 can be used to feed the portholes 117 during rotation to separate material flow of the feedstock (e.g., powder, flake, or billet) into distinct flow streams. This arrangement can help to enable formation of extruded products with hollow cross sections and, depending on the die tool 111 configuration, non-circular interior or exterior profiles (or both). Whichever setup is used, such as the mandrel illustrated in FIGS. 1A-1B, the porthole die configuration in FIGS. 3A-3B, or additional configurations not illustrated, the variation of rotational or axial movements described herein can be used with any number of die face configurations or associated mandrels.

[0039] FIG. 4 illustrates a schematic view of a shear-assisted extrusion system 400. The shear-assisted extrusion system 400 can be or can include a ShAPE machine, an FE machine, or a modified conventional extrusion machine or press in a horizonal or vertical configuration that can be similar to the system 100 discussed above or can be or include any of the machines or systems discussed below. The shear-assisted extrusion system 400 can be configured or can be operable to perform one or more ShAPE operations (or friction stir extrusion operations) such as direct or indirect ShAPE extrusion to generate extrudate using various stocks, spindles, and die tools, as discussed in further detail below.

[0040] The shear-assisted extrusion system 400 can include a headstock 410, which can be similar to the die assembly 110 discussed above with reference to FIG.1. The headstock 410 can be a die assembly that can include a spindle housing 436 and a spindle 438 connected thereto. The spindle 438 can be rotatable with respect to the spindle housing 436. The headstock 410 and the die tool 411 can be axially fixed along a central axis A. The headstock 410 can also include a die tool 411 that can be similar to the die tool 111 such that the die tool 411 can be rotatable with the spindle 438 to engage billet material to form extrudate.

[0041] The shear-assisted extrusion system 400 can also include a container 412, which can be a midstock, mounted to or mounted on tie rods 439. The tie rods 439 can be connected to the spindle housing 436 and the tie rods 439 can be the same or different on either side of the midstock The container 412 can be configured to support feedstock material at least partially therein. The container 412 can be translatable along the tie rods 439 along the central axis A between a disengaged configuration and an engaged configuration. In the disengaged configuration, the container 412 can be movable along the central axis, such as for loading of billet material and service. In the engaged configuration, the container 412 can be engaged with the spindle housing 436 to resist rotation of the container 412 relative to the housing 436 and can provide radial and axial reaction forces and precision alignment that can be required by the nature of the ShAPE or FE process.

[0042] The shear-assisted extrusion system 400 can also include a ram assembly 440 or tailstock. The tie rods 439 can be connected to the ram assembly 440, and can be the same or different tie rods 439 that connect the container 412 to the spindle housing 436. The ram assembly 440 can include a stem 442 configured to translate along the central axis A relative to the spindle 438, the die tool 411, and the container 412 to generate an axial extrusion force between the feedstock material and the die tool 411. In this way, the torque of the shear-assisted extrusion system 400 can be self-contained between the headstock 410 and the container 412 such that torque is not transmitted (or is limited in transmission) to the tie rods (e.g., the tie rods 439) or the ram assembly. This can help to reduce required modifications such as reinforcement of structural components of a direct extrusion machine to become a shear-assisted extrusion system.

[0043] FIG. 5 illustrates an isometric view of a portion of a shear-assisted extrusion or friction extrusion system 500. FIG. 6 illustrates a cross-sectional view of a portion of the shear-assisted extrusion or friction extrusion system 500. FIGS. 5 and 6 are discussed together below. The shear-assisted extrusion or friction extrusion system 500 can be or can include a ShAPE machine or a friction extrusion machine that can be similar to the system 100 discussed above or can be or include any of the ShAPE or friction extrusion machines discussed below.

[0044] The shear-assisted extrusion or friction extrusion system 500 can include a headstock 510 (or a die assembly, or a spindle assembly, or a spindle), a container 512 (or a cannister or a midstock), and a ram assembly 540 (or a tailstock or a ram)including a stem 542. The shear-assisted extrusion or friction extrusion system 500 can also include a gearbox 544 and motors 546 connected thereto. The motors 546 can be alternating current (AC), direct current (DC), servo, pulse-width modulated (PWM) electric motors, or hydraulic motors operable to rotate the headstock 510 (e.g., the spindle thereof). The motors 546 can be configured to drive the gearbox 544, which can in turn drive the spindle to rotate the die tool relative to the container 512, as discussed in further detail below. The gearbox can include a housing and one or more gear trains connected to the motors 546 and configured to transmit rotation from the motors 546 to the cannister or the die tool, as discussed in further detail below.

[0045] FIGS. 5 and 6 also show that the shear-assisted extrusion or friction extrusion system 500 can include a carriage 548 connected to the container 512 and supported by rails 550. The carriage 548 can be a relatively rigid structure including one or more plates, trusses, arms or the like. The carriage 548 can be configured to support the container 512 with respect to or on the rails 550. Together, the carriage 548 and the rails 550 can allow the container 512 to translate with respect to the headstock 510 and the ram assembly 540, such as between extrusion operations, for example, for loading of billet material into the container 512.

[0046] FIG. 6 shows that the headstock 510 can include a die tool 511, a spindle housing 536, and a spindle 538 (which can be a body). The die tool 511 can be similar to the die tool 111 discussed above. The spindle housing 536 can be connected to the gearbox 544 such that the spindle housing 536 can support the gearbox 544. The spindle 538 can be connected to the spindle housing 536, can be supported by the spindle housing 536, and can be rotatable with respect to the spindle housing 536. The headstock 510 can also include a drive gear 552 that can be connected to the spindle 538 such that the drive gear 552 is rotatable with the spindle 538. In some examples, the drive gear 552 can be bolted to the spindle 538 such that the drive gear 552 can be replaceable. The drive gear 552 can be engaged with the gearbox 544 such as to allow the gearbox 544 to drive the drive gear 552, the spindle 538, and the die tool 511 with respect to the container 512 and the spindle housing 536.

[0047] FIG. 6 also shows that the shear-assisted extrusion or friction extrusion system 500 can include a liner 530, which can be connected to an inner surface of the container 512, and can be configured to support billet material at least partially therein. The stem 542 can also be configured to translate within and relative to the liner 530. The ram assembly 540 can also include a stem tip or mandrel 554configured to interface with the billet material such as to help form a desired shape of the extrudate. The mandrel 554 can have a portion protruding or extending into the billet cavity depending on the desired final shape of extrudate.

[0048] FIGS. 5 and 6 also show that the headstock 510 can include a first bearing assembly 556 and a second bearing assembly 558. The first bearing assembly 556 can be engaged with the drive gear 552 (or another portion of the spindle 538) and the housing 536. The second bearing assembly 558 can be engaged with the housing 536 and the spindle 538 to allow relative rotation of the spindle 538 and the drive gear 552 with respect to the housing 536.

[0049] Each of the first bearing assembly 556 and second bearing assembly 558 can include one or more bearings configured to support rotation of the spindle or spindle 538 (and drive gear 552) with respect to the spindle housing 536. Each of the first bearing assembly 556 and the second bearing assembly 558 can be spherical roller thrust bearing, roller bearings, ball bearings, needle bearings, cylindrical bearings, hydrodynamic bearings, or the like.

[0050] FIG. 7 illustrates a cross-sectional view of a portion of the shear-assisted extrusion or friction extrusion system 500. The shear-assisted extrusion or friction extrusion system 500 of FIG. 7 can be consistent with the shear-assisted extrusion or friction extrusion system 500 discussed above; FIG. 7 shows a force path F and a torque path T of the shear-assisted extrusion or friction extrusion system 500.

[0051] More specifically, FIG. 7 shows, via the force path F, that an axial force delivered by the ram assembly 540 to the billet and the die tool can be delivered to billet material but can also be or create a reaction force transferred through the liner 530, through the container 512, through a housing of the gearbox 544, through the spindle housing 536, to the first bearing assemblies 556 and 558, to the spindle 538 and the drive gear 552, and to the die tool 511.

[0052] FIG. 7 also shows, via the torque path T, that the torque generated by the motors 546 and delivered to the spindle 538 and the die tool 511 via the gearbox 544 and the drive gear 552 can cause a reaction torque between the billet material and the canister or container 512. The container 512 can include a keyed interface with the gearbox 544 (shown in further detail below) that can allow the reaction torque to be transferred into a housing of the gearbox 544, back to the housing 536, and back to the spindle 538 and the drive gear 552. In this way, the torque of the shear-assisted extrusion or friction extrusion system 500 can be self-contained between theheadstock 510 and the container 512 such that torque is not transmitted (or is limited in transmission) to the tie rods (e.g., the tie rods 439) or the ram assembly 540 or machine frame. This can help to reduce required modifications, such as reinforcement of structural components, of or to a direct extrusion machine to allow such a direct extrusion machine become a shear-assisted extrusion system, such as the shear- assisted extrusion or friction extrusion system 500, thereby allowing an existing extrusion system to be able to perform ShAPE or FE at all.

[0053] FIG. 8 illustrates a cross-sectional view of a portion of a shear-assisted extrusion system. FIG. 9 illustrates a cross-sectional view of a portion of a shear- assisted extrusion system. FIGS. 8 and 9 are discussed together below. The shear- assisted extrusion or friction extrusion system 500 of FIGS. 8 and 9 can be consistent with the shear-assisted extrusion or friction extrusion system 500 discussed above; FIGS. 8 and 9 show, in part, how the shear-assisted extrusion or friction extrusion system 500 can operate.

[0054] More specifically, FIGS. 8 and 9 show that the container 512 can be translatable, such as via the carriage 548, along the central axis A between a disengaged configuration (shown in FIG. 8) and an engaged configuration (shown in FIG. 9). In the disengaged configuration of FIG. 8, the container 512 can be movable along the central axis A and disengaged from the die tool 511 and the gearbox 544. In the engaged configuration, the container 512 can be engaged with the spindle housing 536, or a housing of the gearbox 544, which can help to resist rotation of the container 512 relative to the housing 536, and can help to reduce torque transmitted beyond the container 512, such as to the carriage 548. Such an arrangement can help achieve loose positional tolerances that can be provided by the system 500 during translation and the tight tolerances provided by the system 500 during engagement or operation of the system 500.

[0055] FIG. 10 illustrates a cross-sectional view of a portion of the shear-assisted extrusion or friction extrusion system 500. FIG. 11 illustrates a cross-sectional view of a portion of the shear-assisted extrusion or friction extrusion system 500. FIGS. 10 and 11 are discussed together below. The shear-assisted extrusion or friction extrusion system 500 of FIGS. 10 and 11 can be consistent with the shear-assisted extrusion or friction extrusion system 500 discussed above; FIGS. 10 and 11 show additional details of the shear-assisted extrusion or friction extrusion system 500.

[0056] For example, FIG. 10 shows that the shear-assisted extrusion or friction extrusion system 500 can include keys 560 (or locking features or interlocking features), which can be projections, protuberances, or the like. The shear-assisted extrusion or friction extrusion system 500 can include one or more keys 560 such as1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 15, 20, or the like, where an axially symmetric layout can be preferred. The keys 560 can be connected (e.g., bolted, welded, riveted, integrally formed, or the like) to the gearbox 544 (such as a housing thereof) or the spindle housing 536. The keys 560 can extend from away from the drive gear 552 toward the container 512. The keys 560 can have a shape of a rectangular prism, but can have others shapes in other examples, such as a wedge, a cylinder (or portion thereof), a hexagonal prism, or the like.

[0057] FIG. 11 shows that the container 512 can include keyways 562 located at least partially in the 512. The keyways 562 can be recesses, openings, or the like. The keyways 562 can extend at least partially into a surface of the container 512 that faces the headstock 510. The container 512 can include one or more keyways 562 such as 1,2, 3, 4, 5, 6, 7, 8, 9, 10, 15, 20, or the like. In some examples, the container 512 can include the same number and layout of keyways 562 as keys 560. In operation of some examples, each of the keyways 562 can be configured to receive, respectively, one of the keys 560 at least partially therein when the container 512 translates to the engaged configuration, such as to help transfer torque or limit rotation of the container 512 with respect to the spindle housing 536. Such an interface between the container 512 and the headstock 510 can position or locate the container 512 radially with respect to the headstock 510 (and the die tool 511) such as to help to increase positional accuracy (or axial positioning accuracy) between the container 512 and the headstock 510 (and therefore the die tool 511) about 25 times more than a standard extrusion press, while simultaneously reacting to nearly all system torque and about 70 percent of the axial process force.

[0058] FIG. 10 also shows how the drive gear 552 can be connected to the spindle 538. The drive gear 552 can include a one or more bore 564 extending at least partially through a body of the drive gear 552. Also, the spindle 538 can include a bore 566 extending at least partially into the spindle 538. The bore 566 can be optionally threaded and can be configured to receive a bolt 568. The bolt 568 can be threadably secured to the bore 566. The bolt 568 can thereby releasably secure the spindle 538 to the drive gear 552. The shear-assisted extrusion or friction extrusionsystem 500 can include one or more bolts, such as 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, or the like to secure the drive gear 552 to the spindle 538. This arrangement is also show in FIG. 14, discussed below.

[0059] FIG. 12 illustrates an isometric view of a portion of the shear-assisted extrusion or friction extrusion system 500. The shear-assisted extrusion or friction extrusion system 500 of FIG. 12 can be consistent with the shear-assisted extrusion or friction extrusion system 500 discussed above; FIG. 12 shows additional details of the gearbox 544. For example, FIG. 12 shows that the gearbox 544 can include a housing 570, which can be connected to the spindle housing 536. The housing 570 can at least partially enclose one or more gears or geartrains of the gearbox 544. In some examples, the housing 570 can be or can be incorporated into the spindle housing 536. That is, the spindle housing 536 and the housing 570 can be integrally formed.

[0060] The gearbox 544 can also include one or more driven gear 572 connected to a shaft of one or more motor 546. The gearbox 544 can also include a reducing gear 574. Any of the gears of the gearbox 544 can be spur gears, bevel gears, worm gears, helical gears, or the like. In some examples, the reducing gear 574 can extend at least partially out of the housing 570 to engage the drive gear 552. In some example, the housing 570 can at least partially enclosed the drive gear 552. In some examples, the gearbox 544 can include a planetary gearbox or the like.

[0061] The reducing gear 574 can be engaged with the driven gear 572 and the drive gear 552 and can optionally be at least partially supported by the gearbox 544. The gearbox 544 can also include one or more bearings or supports for any of the driven gear 572, reducing gear 574, drive gear 552, or any other gear. Each motor 546 can include a driven gear 572 and a reducing gear 574 that interfaces with the drive gear 552 such that multiple motors can be used to drive the drive gear 552. For example, two motors 546 can be used, as previously discussed, however, 3, 4, 5, 6, 7, 8, 9, 10, or the like motors can be used. A symmetric placement of these motors 546 about the central axis can be used.

[0062] FIG. 13 illustrates a cross-sectional view of a portion of the shear-assisted extrusion or friction extrusion system 500. The shear-assisted extrusion or friction extrusion system 500 of FIG. 13 can be consistent with the shear-assisted extrusion or friction extrusion system 500 discussed above; FIG. 13 shows additional details of the shear-assisted extrusion or friction extrusion system 500.

[0063] For example, FIG. 13 shows that the die tool 511 can include an outer surface 576 and splines 578 connected to the die tool 511. The splines 578 can extend axially (along a direction of the central axis A) along the outer surface 576 and the splines 578 can extend radially outward from the die tool 511. The splines 578 can be ridges, projections, protuberances, or the like.

[0064] FIG. 13 also shows that the drive gear 552 can include a central bore 580, which can extend along or can be coaxial with the central axis A. The central bore 580 can be configured (e.g., sized or shaped) to receive the die tool 511 at least partially therein to help secure the die tool 511 to the drive gear 552. The drive gear 552 can also include splines or slots 584 extending into an inner surface 582 of the drive gear 552, where the inner surface 582 can at least partially define the central bore 580. The slots 584 can extend radially outward from the inner surface 582 and can extend axially parallel to the central axis A. The slots 584 can be configured to receive the splines 578 of the die tool 511 such that the splines 578 are at least partially insertable the slots 584, which can help to limit or prevent rotation of the die tool 511 with respect to the drive gear 552 and the spindle 538. In some examples, the splines 578 can be integrally formed into the die tool 511. In some examples, the splines 578 can be replaceable such that the splines 578 can be insertable into slots of the die tool 511.

[0065] FIG. 14 illustrates a cross-sectional view of a portion of a shear-assisted extrusion system. The shear-assisted extrusion or friction extrusion system 500 of FIG. 14 can be consistent with the shear-assisted extrusion or friction extrusion system 500 discussed above; FIG. 14 shows additional details of the shear-assisted extrusion or friction extrusion system 500.

[0066] For example, FIG. 14 shows that the 536 can define or include a first bore 586 and a second bore 588. In some examples, the first bore 586 and the second bore 588 can be a common bore. The shear-assisted extrusion or friction extrusion system 500 can also include a first biasing assembly 590 and a second biasing assembly 592. Each of the first biasing assembly 590 and the second biasing assembly 592 can include one or more biasing elements such as a spring (e.g., compression spring, extension spring, coil spring, Belville washer, or the like). For example, each of the first biasing assembly 590 and the second biasing assembly 592 can include 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, or the like biasing elements. Also, the shear-assisted extrusion or friction extrusion system 500 can include one ormore first biasing assembly and one or more second biasing assembly, for example, spaced circumferentially around the spindle housing 536, which can help evenly load the first bearing assembly 556 and the second bearing assembly 558. In other examples, the first biasing assembly 590 can be replaced with a single large Belleville washer that extends around a circumference of the spindle housing 536 and the second biasing assembly 592 can be similarly configured.

[0067] The first biasing assembly 590 can be engaged with the spindle housing 536 (e.g., via the first bore 586) and the first biasing assembly 590 can be engaged with the first bearing assembly 556 such as to pre-load the first bearing assembly 556 or bias the first bearing assembly 556 toward the drive gear 552. Similarly, the second biasing assembly 592 can be engaged with the spindle housing 536 (e.g., via the second bore 588) and the second biasing assembly 592 can be engaged with the second bearing assembly 558 such as to pre-load the second bearing assembly 558 or bias the second bearing assembly 558 toward a flange 559 of the spindle 538.

[0068] FIG. 14 also shows that the drive gear 552 can include a tool holder 594 (or tool bore) that can be coaxial or centered with the central axis A and the central bore 580. The tool holder 594 can be larger (e.g., can have a radius or diameter that is larger) than the central bore 580. The tool holder 594 can be configured (e.g., sized or shaped) to receive a centering ring 596 at least partially therein. The centering ring 596 can have an outer surface configured to engage with the tool holder 594 and an inner surface configured to receive at least a portion of the die tool 511 at least partially therein. The centering ring 596 can be machined or manufactured to a relatively high manufacturing tolerance to help position or align the die tool 511 about the central axis A.

[0069] FIG. 14 also shows that the die tool 511 can include a flange 598 extending radially outward from the outer surface 576 of the die tool 511. The flange 598 can be larger than the radius or diameter of the outer surface 576 such that the flange 598 can engage a face of the centering ring 596 or the tool holder 594. Also, because ethe central bore 580 can be smaller than an outer diameter (and an inner dimeter of the centering ring 596), the centering ring 596 can engage a face of the drive gear 552. In this way, axial force applied to the die tool 511 can be transferred from the flange 598 into the centering ring 596 and then to the drive gear 552, helping to maintain a position or location of the die tool 511 during operations. In some examples, the outer surface 576 of the die tool 511 can be tapered and an inner surface of the centeringring 596 can be tapered (in a complementary way) such that the outer surface 576 and the centering ring 596 can mate or engage in a taper-to-taper interface, which can help increase positional accuracy or precision of the die tool 511.

[0070] FIG. 14 also shows that the shear-assisted extrusion or friction extrusion system 500 can include a first seal 561 located between the spindle housing 536 and the flange 559 and configured to retain oil or other lubricating fluid. Similarly, the shear-assisted extrusion or friction extrusion system 500 can include a second seal 563 between the drive gear 552 and the gearbox 544 and configured to retain oil or other lubricating fluid. The shear-assisted extrusion or friction extrusion system 500 can also include one or more seals 565 between the gearbox 544 and the spindle housing 536, and the shear-assisted extrusion or friction extrusion system 500 can include various other seals, as required, to retain oil or other lubricating or cooling fluid.

[0071] FIG. 15 illustrates a schematic view of a shear-assisted extrusion system 1500. The shear-assisted extrusion or friction extrusion system 500 can be similar to the shear-assisted extrusion or friction extrusion system 500 discussed above in that the shear-assisted extrusion system 1500 can include similar components; however, the shear-assisted extrusion system 1500 can be configured such that a container and ram can rotate and a die tool is fixed relative to the container and the ram.

[0072] As shown in FIG. 15, the shear-assisted extrusion system 1500 can include a headstock 1510 (which can be or can be similar to the headstock 510) that can include a spindle housing 1536 and a spindle 1538 (which can be or can include a body). The spindle 1538 can be driven to rotate with respect to the spindle housing 1536 by one or more motors and a gearbox (e.g., the motors 546 and the gearbox 544). FIG. 15 also shows that the shear-assisted extrusion system 1500 can include a container 1512 (or cannister) configured to support billet material at least partially therein. The container 1512 can be secured to a radially inner portion of the spindle 1538 such that the container 1512 can rotate with the spindle 1538. The shear-assisted extrusion system 1500 can also include a ram 1540 including a dummy block 1591 (or stem) configured to rotate with the headstock 1510 with respect to a die tool 1511.

[0073] The die tool 1511 (which can be similar to the die tool 511) can be supported by a die holder 1593 such as to hold the die tool 1511 stationary (e.g., limit or prevent rotation of the die tool 1511) during extrusion. In this way, an extrusion system can be modified to become the shear-assisted extrusion or friction extrusionsystem 500 (or shear-assisted extrusion system 1500) to perform ShAPE or friction stir extrusion with a rotating container or cannister and a fixed die.

[0074] FIG. 16 illustrates a schematic view of the method 1600, in accordance with at least one example of this disclosure. The method 1600 can be a method of modifying an extrusion system to become a ShAPE system or a friction stir extrusion system. 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 steps or operations of the method 1600 can be omitted or can be performed multiple times. The method 1600 as discussed includes operations that can be performed by multiple different actors, devices, or systems. It should be 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.

[0075] The method 1600 can begin at step 1602 where components of the existing extrusion system can be removed. For example, the existing die holder can be removed and the existing container can be removed (optionally a carriage for the container can be removed). At step 1604, a headstock can be connected to an existing frame or extrusion system. For example, the headstock 510 (e.g., including the spindle housing 536, spindle 538, or drive gear 552) can be installed or connected.

[0076] At step 1606, a carriage can be installed or connected. For example, the carriage 548 can be connected to rails 550 or to tie rods 439. At step 1608 a container can be installed or connected to a carriage. For example, the container 512 can be connected to the carriage 548, such as to allow the carriage 548 and the container 512 to translate relative to the ram assembly 540 and the headstock 510.

[0077] At step 1610, a gearbox can be connected to the headstock. For example, the gearbox 544 can be connected to the headstock 510. At step 1612, motors can be connected to the gearbox. For example, the motors 546 can be connected to the gearbox 544. In this way, a standard extrusion machine can be converted to a ShAPE system or a friction stir extrusion system. At an optional step 1614, the control system for the motor can be fully or partially integrated of in with the press’s control system. This step can include part (or full) integration of the motor, its controller, etc. into the control system of the existing press or machine. This can allow for fewer humanmachine-interface or computer to control everything. Also, the control system can beintegrated into the safety hardware, such as but not limited to estops, limit switches, etc.

[0078] FIG. 17 illustrates a block diagram of an example machine 1700 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 1700. Circuitry (e.g., processing circuitry) is a collection of circuits implemented in tangible entities of the machine 1700 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 1700 follow.

[0079] In alternative embodiments, the machine 1700 may operate as a standalone device or may be connected (e.g., networked) to other machines. In a networked deployment, the machine 1700 may operate in the capacity of a server machine, a client machine, or both in server-client network environments. In an example, the machine 1700 may act as a peer machine in peer-to-peer (P2P) (or other distributed) network environment. The machine 1700 may be a personal computer (PC), a tabletPC, 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.

[0080] The machine (e.g., computer system) 1700 may include a hardware processor 1702 (e.g., a central processing unit (CPU), a graphics processing unit (GPU), a hardware processor core, or any combination thereof), a main memory 1704, a static memory (e.g., memory or storage for firmware, microcode, a basic-input- output (BIOS), unified extensible firmware interface (UEFI), etc.) 1706, and mass storage 1708 (e.g., hard drive, tape drive, flash storage, or other block devices) some or all of which may communicate with each other via an interlink (e.g., bus) 1730. The machine 1700 may further include a display unit 1710, an alphanumeric input device 1712 (e.g., a keyboard), and a user interface (UI) navigation device 1714 (e.g., a mouse). In an example, the display unit 1710, input device 1712 and UI navigation device 1714 may be a touch screen display. The machine 1700 may additionally include a storage device (e.g., drive unit) 1708, a signal generation device 1718 (e.g., a speaker), a network interface device 1720, and one or more sensors 1716, such as a global positioning system (GPS) sensor, compass, accelerometer, or other sensor. The machine 1700 may include an output controller 1728, 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.).

[0081] Registers of the processor 1702, the main memory 1704, the static memory 1706, or the mass storage 1708 may be, or include, a machine readable medium 1722 on which is stored one or more sets of data structures or instructions 1724 (e.g., software) embodying or utilized by any one or more of the techniques or functions described herein. The instructions 1724 may also reside, completely or at least partially, within any of registers of the processor 1702, the main memory 1704, the static memory 1706, or the mass storage 1708 during execution thereof by the machine 1700. In an example, one or any combination of the hardware processor1702, the main memory 1704, the static memory 1706, or the mass storage 1708 may constitute the machine readable media 1722. While the machine readable medium 1722 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, and / or associated caches and servers) configured to store the one or more instructions 1724.

[0082] The term “machine readable medium” may include any medium that is capable of storing, encoding, or carrying instructions for execution by the machine 1700 and that cause the machine 1700 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 medium comprises 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.

[0083] The instructions 1724 may be further transmitted or received over a communications network 1726 using a transmission medium via the network interface device 1720 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 networkinterface device 1720 may include one or more physical jacks (e.g., Ethernet, coaxial, or phonejacks) or one or more antennas to connect to the communications network 1726. In an example, the network interface device 1720 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 1700, 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

[0084] 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.

[0085] Example l is a system for performing shear-assisted extrusion or friction 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 comprising: a housing; and a spindle secured to the housing, the spindle rotatable, together with the die tool, relative to the housing 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 translatable along the central axis between a disengaged configuration and an engaged configuration wherein the midstock is engaged with the housing to resist rotation of the midstock relative to the housing; and a tailstock configured to translate along the central axis relative to the headstock and the midstock to generate an axial extrusion force between the feedstock material and the die tool, the midstock configured to transfer at least a portion of the axial extrusion force to the spindle housing.

[0086] In Example 2, the subject matter of Example 1 optionally includes wherein the midstock is translatable along the central axis when the midstock is disengaged from the housing of the headstock.

[0087] In Example 3, the subject matter of any one or more of Examples 1-2 optionally include a gearbox engaged with the spindle; and one or more motors connected to the gearbox to drive the gearbox to rotate the spindle and the die tool relative to the tailstock and the midstock.

[0088] In Example 4, the subject matter of Example 3 optionally includes wherein the spindle comprises: a body; and a drive gear connected to the body, the drive gear engaged with the gearbox to receive rotational input from the one or more motors to rotate the body and the drive gear with respect to the housing.

[0089] In Example 5, the subject matter of Example 4 optionally includes wherein the drive gear is bolted to the body.

[0090] In Example 6, the subject matter of any one or more of Examples 4-5 optionally include wherein the drive gear at least partially defines a tool bore configured to receive the die tool at least partially therein.

[0091] In Example 7, the subject matter of Example 6 optionally includes a centering ring located at least partially within the tool bore, the centering ring figured to receive the die tool at least partially therein.

[0092] In Example 8, the subject matter of Example 7 optionally includes a plurality of splines connected to the die tool and at least partially insertable into slots formed into the drive gear or the spindle, to limit rotation of the die tool with respect to the spindle.

[0093] In Example 9, the subject matter of any one or more of Examples 4-8 optionally include a first bearing assembly engaged with the drive gear and the housing; and a second bearing assembly engaged with the housing and the body to allow relative rotation of the body and the drive gear with respect to the housing.

[0094] In Example 10, the subject matter of Example 9 optionally includes one or more biasing elements engaged with the first bearing assembly and the housing to bias the first bearing assembly toward the drive gear.

[0095] In Example 11, the subject matter of Example 10 optionally includes a second set of biasing elements engaged with the second bearing assembly and the housing to bias the second bearing assembly toward a flange of the body.

[0096] In Example 12, the subject matter of any one or more of Examples 3-11 optionally include a plurality of keys connected to a housing or the gearbox; and a plurality of keyways located at least partially in the midstock, the plurality of keyways configured to receive, respectively, the plurality of keys when the midstock translates to the engaged configuration.

[0097] In Example 13, the subject matter of any one or more of Examples 1-12 optionally include 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.

[0098] In Example 14, the subject matter of Example 13 optionally includes a container connected to the midstock and configured to support the feedstock material at least partially therein.

[0099] Example 15 is a system for performing shear-assisted extrusion or friction extrusion, the system comprising: a die tool including a face configured to engage and plasticize a portion of feedstock material engaged with the face; a rotating assembly comprising: a housing; and a spindle connected to the housing and connected to the die tool, the spindle rotatable together with the die tool relative to the housing 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 die tool; a container configured to support the feedstock material at least partially therein, the container translatable along the central axis between a disengaged configuration and an engaged configuration wherein the container is engaged with the housing to resist rotation of the container relative to the housing; and a ram configured to translate along the central axis relative to the die tool and the container to generate an axial extrusion force between the feedstock material and the die tool.

[0100] In Example 16, the subject matter of Example 15 optionally includes wherein the container is translatable along the central axis when the container is disengaged from the housing of the headstock.

[0101] In Example 17, the subject matter of any one or more of Examples 15-16 optionally include a gearbox engaged with the spindle; and one or more motors connected to the gearbox to drive the gearbox to rotate the spindle and the die tool relative to the housing and the container.

[0102] In Example 18, the subject matter of Example 17 optionally includes wherein a housing of the gearbox and the housing of the rotating assembly are integrally formed.

[0103] In Example 19, the subject matter of any one or more of Examples 17-18 optionally include wherein the spindle comprises: a body; and a drive gear connected to the body, the drive gear engaged with the gearbox to receive rotational input from the one or more motors to rotate the spindle with respect to the housing.

[0104] In Example 20, the subject matter of Example 19 optionally includes wherein the drive gear includes a tool bore configured to receive the die tool at least partially therein.

[0105] In Example 21, the subject matter of any one or more of Examples 15-20 optionally include a control system configured to operate the spindle.

[0106] Example 22 is a shear-assisted extrusion system or friction extrusion system including any features, components, or steps discussed herein.

[0107] Example 23 is a method comprising equipping a non-shear-assisted ram extrusion system with a system including any features, components, or steps discussed herein.

[0108] In Example 24, the apparatuses or method of any one or any combination of Examples 1 - 23 can optionally be configured such that all elements or options recited are available to use or select from.

[0109] 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.

[0110] 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 thefollowing 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.

[0111] 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.

[0112] 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 or friction 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 comprising: a housing; and a spindle secured to the housing, the spindle rotatable, together with the die tool, relative to the housing 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 translatable along the central axis between a disengaged configuration and an engaged configuration wherein the midstock is engaged with the housing to resist rotation of the midstock relative to the housing; and a tailstock configured to translate along the central axis relative to the headstock and the midstock to generate an axial extrusion force between the feedstock material and the die tool, the midstock configured to transfer at least a portion of the axial extrusion force to the spindle housing.

2. The system of claim 1, wherein the midstock is translatable along the central axis when the midstock is disengaged from the housing of the headstock.

3. The system of claim 1, comprising: a gearbox engaged with the spindle; and one or more motors connected to the gearbox to drive the gearbox to rotate the spindle and the die tool relative to the tailstock and the midstock.

4. The system of claim 3, wherein the spindle comprises: a body; and a drive gear connected to the body, the drive gear engaged with the gearbox to receive rotational input from the one or more motors to rotate the body and the drive gear with respect to the housing.

5. The system of claim 4, wherein the drive gear is bolted to the body.

6. The system of claim 4, wherein the drive gear at least partially defines a tool bore configured to receive the die tool at least partially therein.

7. The system of claim 6, comprising: a centering ring located at least partially within the tool bore, the centering ring figured to receive the die tool at least partially therein.

8. The system of claim 7, comprising: a plurality of splines connected to the die tool and at least partially insertable into slots formed into the drive gear or the spindle, to limit rotation of the die tool with respect to the spindle.

9. The system of claim 4, comprising: a first bearing assembly engaged with the drive gear and the housing; and a second bearing assembly engaged with the housing and the body to allow relative rotation of the body and the drive gear with respect to the housing.

10. The system of claim 9, comprising: one or more biasing elements engaged with the first bearing assembly and the housing to bias the first bearing assembly toward the drive gear.

11. The system of claim 10, comprising: a second set of biasing elements engaged with the second bearing assembly and the housing to bias the second bearing assembly toward a flange of the body.

12. The system of claim 3, comprising: a plurality of keys connected to a housing or the gearbox; and a plurality of keyways located at least partially in the midstock, the plurality of keyways configured to receive, respectively, the plurality of keys when the midstock translates to the engaged configuration.

13. 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.

14. The system of claim 13, comprising: a container connected to the midstock and configured to support the feedstock material at least partially therein.

15. A system for performing shear-assisted extrusion or friction extrusion, the system comprising: a die tool including a face configured to engage and plasticize a portion of feedstock material engaged with the face; a rotating assembly comprising: a housing; and a spindle connected to the housing and connected to the die tool, the spindle rotatable together with the die tool relative to the housing 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 die tool; a container configured to support the feedstock material at least partially therein, the container translatable along the central axis between a disengaged configuration and an engaged configuration wherein the container is engaged with the housing to resist rotation of the container relative to the housing; anda ram configured to translate along the central axis relative to the die tool and the container to generate an axial extrusion force between the feedstock material and the die tool.

16. The system of claim 15, wherein the container is translatable along the central axis when the container is disengaged from the housing of the headstock.

17. The system of claim 15, comprising: a gearbox engaged with the spindle; and one or more motors connected to the gearbox to drive the gearbox to rotate the spindle and the die tool relative to the housing and the container.

18. The system of claim 17, wherein a housing of the gearbox and the housing of the rotating assembly are integrally formed.

19. The system of claim 17, wherein the spindle comprises: a body; and a drive gear connected to the body, the drive gear engaged with the gearbox to receive rotational input from the one or more motors to rotate the spindle with respect to the housing.

20. The system of claim 19, wherein the drive gear includes a tool bore configured to receive the die tool at least partially therein.

21. The system of claim 15, comprising: a control system configured to operate the spindle.

22. A shear-assisted extrusion system or friction extrusion system including any features, components, or steps discussed herein.

23. A method comprising equipping a non-shear-assisted ram extrusion system with a system including any features, components, or steps discussed herein.

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