ShAPE Extrusion of Slotted Al-NCCF Feedstock for Hollow Profiles
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Solution Overview
Problem
Current methods for producing materials like magnesium and aluminum alloys with hollow cross sections face challenges such as the formation of brittle intermetallic layers, high energy costs, and the need for rare earth elements, which are expensive and limited, making it difficult to achieve strong, corrosion-resistant, and energy-efficient manufacturing processes.
Innovation Solution
The Shear Assisted Processing and Extrusion (ShAPE) technique uses a rotating ram or die to apply both rotational shearing and axial extrusion forces, allowing for the production of metal-NanoCrystalline Carbon Forms (NCCF) extrusions with improved strength, conductivity, and corrosion resistance without the need for additional processing steps or rare earth elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional extrusion methods are used to produce magnesium or aluminum alloys with hollow cross sections, then the manufacturing process is simpler, but brittle intermetallic layers form and energy consumption is high
Solution Approach 1:
The patent applies parameter changes by modifying the extrusion process conditions, specifically using a rotating ram that imparts shear forces during extrusion. This changes the mechanical parameters (rotational speed, shear rate) and thermal parameters (frictional heating) to achieve energy-efficient processing while preventing intermetallic layer formation through controlled material flow and reduced dwell time at harmful temperatures
Solution Approach 2:
The patent replaces the conventional linear extrusion mechanism with a rotating ram system that combines axial compression with rotational shear. This mechanical substitution introduces a new mode of deformation (shear-assisted extrusion) that reduces energy consumption by optimizing the stress state during plastic deformation and minimizing redundant work
2Strength
If rare earth elements are added to alloys to impart desired characteristics, then material strength and corrosion resistance are improved, but manufacturing cost increases and material availability decreases
Solution Approach 1:
The patent changes the processing parameters (shear rate, temperature, pressure) to achieve superior material properties without rare earth additions. The shear-assisted extrusion process creates refined grain structures and favorable texture development that inherently enhance strength and corrosion resistance, replacing the need for rare earth element alloying
Solution Approach 2:
The patent creates composite-like microstructures through the extrusion process itself, where controlled grain refinement and phase distribution achieved via shear forces produce materials with enhanced properties comparable to or exceeding rare earth-containing alloys, but using only base metals
3Ease of manufacture
If conventional extrusion processes are used, then production is simpler, but ductility and energy absorption are limited
Solution Approach 1:
The patent changes the deformation parameters by introducing rotational shear during extrusion. This creates a complex stress state (combination of compression and shear) that promotes more uniform plastic deformation, refines grain structure, and develops favorable crystallographic texture, all of which enhance ductility and energy absorption while maintaining production feasibility
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
ShAPE enables the production of lightweight materials with enhanced mechanical and electrical properties, reduced energy consumption, and lower manufacturing costs, achieving 50-100% greater ductility and energy absorption compared to conventional extrusion methods, while also eliminating brittle intermetallic layers and minimizing porosity.
Implementation Method 1
applying a rotational shearing force and an axial extrusion force to a feedstock material
Implementation Method 2
The combination of the rotational and linear forces frictionally heats and/or plasticizes the material
Implementation Method 3
The combination of the rotational and linear forces frictionally heats and/or plasticizes the material
Implementation Method 4
The combination of the rotational and linear forces frictionally heats and/or plasticizes the material at the interface with the die face and causes the plasticized material to flow in a desired direction
Data Source
AI summary
An extrusion feedstock material is provided, the material comprising a length of one material extending from a first end to a second end; and at least one slot extending lengthwise within the one material between the first and second ends of the material. A process for extruding conductive material is also provided, the process comprising providing both rotational and axial forces between a die tool and a length of feedstock material to form an extrusion product, wherein the length of feedstock and conductive material comprise Al and NanoCrystalline Carbon Forms (NCCF). A process for extruding material is provided, the process comprising: providing both rotational and axial forces between a die tool and a length of feedstock material to form an extrusion product, wherein the length of feedstock material comprises: a length of material extending from a first end to a second end; and at least one slot extending lengthwise within the material between the first and second ends of the material. A conductive extrudate material is provided comprising Al and NanoCrystalline Carbon Forms (NCCF).