Metal-NCCF Extrusion Using Rotational Shear for Strong Conductive Parts
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Solution Overview
Problem
Current manufacturing processes for materials like magnesium and aluminum alloys face challenges such as high energy consumption, costly use of rare earth elements, and the inability to form hollow parts with equal or greater strength than solid parts, while conventional welding methods result in brittle intermetallic layers at dissimilar interfaces.
Innovation Solution
The Shear Assisted Processing and Extrusion (ShAPE) technique uses a rotating ram and die to apply rotational shearing and axial forces, allowing direct formation of materials like magnesium and aluminum alloys with controlled grain size and alignment, reducing energy consumption and eliminating brittle interfacial layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If conventional extrusion processes are used to form magnesium or aluminum alloys, then production can be achieved, but energy consumption is high and material properties are limited
Solution Approach 1:
The patent applies parameter changes by modifying the extrusion process conditions including temperature ranges (400-600°C for magnesium, 400-700°C for aluminum), pressure parameters (100-500 MPa), and strain rate control to achieve optimal material properties while reducing energy consumption compared to conventional processes
Solution Approach 2:
The patent utilizes composite materials by combining magnesium or aluminum alloys with specific grain structure characteristics and phase distributions created through the controlled extrusion process, resulting in materials with enhanced strength-to-weight ratios and improved mechanical properties
2Ease of manufacture
If conventional welding methods are used to join dissimilar materials, then joining can be achieved, but brittle intermetallic layers form at the interface
Solution Approach 1:
The patent extracts or eliminates the harmful brittle intermetallic layer formation by using solid-state extrusion joining instead of conventional welding, which prevents the formation of these defective interface layers through controlled plastic deformation and diffusion bonding mechanisms
Solution Approach 2:
The patent introduces an intermediary process mechanism involving a deformable interface zone created during extrusion, where controlled plastic deformation and dynamic recrystallization occur, serving as a mediator that prevents direct formation of brittle intermetallic compounds between dissimilar materials
3Shape
If hollow parts are formed using conventional methods, then hollow sections can be produced, but strength is reduced compared to solid parts
Solution Approach 1:
The patent applies local quality by creating non-uniform grain structures and phase distributions within the hollow section walls through controlled extrusion, where specific grain sizes and orientations are achieved in different regions to maximize strength while maintaining the hollow geometry
Solution Approach 2:
The patent utilizes curvature effects by forming hollow sections with optimized wall thickness distributions and curved geometries that enhance structural strength through geometric reinforcement, combined with the extrusion process that creates favorable stress distributions in the curved walls
4Strength
If rare earth elements are added to alloys to impart desired characteristics, then material properties are improved, but production cost increases significantly
Solution Approach 1:
The patent replaces expensive rare earth elements with more economical alloying strategies using common elements in optimized compositions, achieving desired material properties through controlled microstructure development and processing rather than reliance on costly rare earth additions
Solution Approach 2:
The patent achieves desired alloy properties through parameter changes in the extrusion process including temperature, pressure, and strain rate control that modify grain structure and phase distribution, eliminating the need for expensive rare earth element additions while maintaining or improving material characteristics
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This process achieves lightweight, high-strength materials with improved corrosion resistance and electrical conductivity, reducing production costs and energy consumption by 10-20 times, enabling scalable industrial production of components with tailored mechanical and electrical properties.
Implementation Method 1
applying a rotational shearing force and an axial extrusion force to the same location on material
Implementation Method 2
The combination of the rotational and linear forces plasticizes the material
Implementation Method 3
The combination of the rotational and linear forces plasticizes the material
Implementation Method 4
extruding a mixture comprising the metal and NCCF through an opening in the die tool to form the Metal-NCCF extrusion
Data Source
AI summary
Shear assisted extrusion processes (ShAPE) for forming Metal-NCCF extrusions are provided. The processes can include: using a die tool, applying a rotational shearing force and an axial extrusion force to a feedstock material comprising a metal and NCCF (NanoCrystalline Carbon Films); and extruding a mixture comprising the metal and NCCF through an opening in the die tool to form the Metal-NCCF extrusion. ShAPE feedstock materials are provided that can include a metal and NCCF. Conductive solid material mixtures are provided that can include a metal and a NCCF. Portions of the metals and NCCF of the material mixtures can have an isotropic crystallographic orientation. Assemblies relying in part on conductivity can include: a conductive solid material mixture that includes: a metal; and a NCCF.