ShAPE Hollow Profile Extrusion for Low-Energy Alloy Forming
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Solution Overview
Problem
Current manufacturing methods for producing hollow car or aerospace parts from magnesium or aluminum alloys are inefficient, require high energy costs, and often necessitate the use of rare earth metals, which are expensive and scarce.
Innovation Solution
The Shear Assisted Processing and Extrusion (ShAPE) technique, which applies a combination of rotational shearing and axial extrusion forces to form non-circular hollow-profile extrusions directly from billets, powders, or flakes, without the need for additional processing steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If conventional extrusion processes are used to form hollow parts from magnesium or aluminum alloys, then the manufacturing capability is achieved, but the energy consumption is high and the production cost increases
Solution Approach 1:
The patent applies parameter changes by modifying the extrusion process conditions - specifically using lower temperatures and controlled pressure parameters in the ShAPE process compared to conventional extrusion, thereby reducing energy consumption while maintaining manufacturing capability for hollow parts from magnesium and aluminum alloys
Solution Approach 2:
The patent replaces the conventional mechanical extrusion system with the ShAPE process that uses a rotating ram mechanism, substituting the traditional linear mechanical pressing system with a rotational shear-assisted system that achieves forming with reduced energy input
2Strength
If rare earth metals are added to alloys to impart desired characteristics, then the material properties are improved, but the production cost increases due to expense and scarcity
Solution Approach 1:
The patent changes the material composition parameters by developing alloy formulations that achieve desired strength and material properties through controlled combinations of base metals (magnesium, aluminum) and minimal or no rare earth additions, thereby maintaining performance while reducing cost
Solution Approach 2:
The patent substitutes expensive rare earth metals with cheaper alternative alloying elements or processing-induced microstructural features, using cost-effective compositions that achieve the required material properties without relying on scarce and expensive rare earth additives
3Manufacturing precision
If additional processing steps are used to form hollow structures, then the manufacturing precision is improved, but the process complexity increases
Solution Approach 1:
The patent merges multiple processing steps into a single integrated ShAPE operation, combining hollow section formation, cross-sectional shaping, and material densification into one simultaneous process action, thereby achieving manufacturing precision without increasing process complexity
Solution Approach 2:
The patent creates a universal ShAPE process that can form various hollow cross-sections (circular, rectangular, I-beam, etc.) using the same basic process and tooling approach, making the process multi-functional and eliminating the need for different specialized processes for different geometries
4Productivity
If conventional extrusion methods are used, then the production process is established, but the energy costs are high
Solution Approach 1:
The patent changes the energy-related parameters by conducting extrusion at lower temperatures and with optimized pressure profiles in the ShAPE process, reducing the total energy input required while maintaining or improving production efficiency through the rotational mechanism's continuous material flow
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 significantly reduces energy consumption and production costs, enables the formation of materials with improved strength and corrosion resistance, and allows for the production of high-quality extruded materials with tailored grain sizes and crystallographic orientations.
Implementation Method 1
a rotating ram or die rather than a simply axially fed ram or die used in the conventional extrusion process
Implementation Method 2
plasticized material from a first location, typically on the interface between the material and the scroll face
Implementation Method 3
uses a rotating ram or die rather than a simply axially fed ram or die used in the conventional extrusion process
Data Source
Figure 1a
Figure 1b
Figure 2a
AI summary
A process for forming extruded products using a device having a scroll face configured to apply a rotational shearing force and an axial extrusion force to the same preselected location on material wherein a combination of the rotational shearing force and the axial extrusion force upon the same location cause a portion of the material to plasticize, flow and recombine in desired configurations. This process provides for a significant number of advantages and industrial applications, including but not limited to extruding tubes used for vehicle components with 50 to 100 percent greater ductility and energy absorption over conventional extrusion technologies, while dramatically reducing manufacturing costs.