Shear-Assisted Billet Extrusion for Low-Energy Grain Refinement
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Solution Overview
Problem
Existing manufacturing methods for materials like magnesium and aluminum alloys face challenges such as the formation of brittle intermetallics, high energy costs, and the need for rare earth elements, which hinder the production of lightweight, high-strength components with efficient grain size and alignment.
Innovation Solution
The Shear Assisted Processing and Extrusion (ShAPE) technique uses a rotating ram or die to apply rotational shearing and axial extrusion forces, eliminating the need for pre-heating and reducing energy consumption, while enabling direct formation of materials with controlled grain size and alignment, and allowing for the joining of dissimilar metals without forming brittle interfacial layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If conventional extrusion processes are used to form lightweight alloy components, then material forming capability is achieved, but energy consumption is high and pre-heating is required
Solution Approach 1:
The patent changes the fundamental parameters of the extrusion process by applying rotational shearing forces combined with axial compression, transforming the material through severe plastic deformation rather than conventional thermal softening. This allows cold extrusion of alloys that would traditionally require pre-heating, directly reducing energy consumption while simplifying the manufacturing process
Solution Approach 2:
The rotating ram or die applies dynamic rotational shearing forces to the material during extrusion, creating intense mechanical deformation that facilitates material flow and grain refinement without thermal assistance. This mechanical action replaces the need for pre-heating while maintaining formability
2Strength
If conventional extrusion is used to join dissimilar metals, then material joining capability is achieved, but brittle intermetallic layers form at the interface
Solution Approach 1:
The rotational shearing action creates intense mechanical mixing and deformation at the interface between dissimilar metals during extrusion. This dynamic mechanical process prevents the formation of continuous brittle intermetallic layers by disrupting their growth, while still achieving strong metallurgical bonding through severe plastic deformation and interface consolidation
Solution Approach 2:
The patent changes the deformation parameters by applying intense shear strains and rotational forces that fundamentally alter the interface evolution between dissimilar metals. Instead of allowing equilibrium intermetallic growth, the dynamic mechanical process creates a refined, dispersed intermetallic distribution that maintains strength while eliminating brittleness
3Manufacturing precision
If traditional extrusion processes are used, then material forming capability is achieved, but grain size control and alignment are insufficient
Solution Approach 1:
The patent merges multiple processing functions into a single extrusion operation. The rotational shearing and axial compression simultaneously achieve material forming, grain refinement, and crystallographic alignment in one continuous process, eliminating the need for separate preprocessing and postprocessing steps while achieving superior grain size control
Solution Approach 2:
The intense dynamic deformation from rotational shearing creates severe plastic deformation that rapidly refines grain structure and aligns crystallographic orientations during the extrusion process itself. This in-situ grain refinement achieves precise microstructural control without requiring additional processing steps
4Strength
If rare earth elements are added to alloys to improve properties, then material performance is enhanced, but manufacturing cost increases
Solution Approach 1:
The patent changes the processing parameters through rotational shearing and severe plastic deformation, which fundamentally alter the material's microstructure and mechanical properties. This process-induced property enhancement replaces the need for expensive rare earth alloying, achieving improved strength and performance through mechanical refinement rather than chemical composition modification
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 components with improved mechanical properties and corrosion resistance, reducing energy consumption by up to 90% and manufacturing costs, while enabling the use of non-rare earth alloys, and allowing for the production of high entropy alloys in a single step.
Implementation Method 1
applying a rotational shearing force and an axial extrusion to the same location on the feedstock material
Implementation Method 2
applying a rotational shearing force and an axial extrusion to the same location on the feedstock material
Data Source
AI summary
The present disclosure provides methods for preparing an extruded product from a solid billet. The methods can include providing an as-cast billet for extrusion; applying a simultaneous rotational shear and axial extrusion force to the as-cast billet to plasticize the as-cast billet; and extruding the plasticized as-cast billet with an extrusion die to form an extruded product. Methods for preparing extruded products from billets can also include: providing a billet for extrusion; while maintaining a majority of the billet below 100° C., applying a simultaneous rotational shear and axial extrusion force to one end of the billet to plasticize the one end of the billet; and extruding the plasticized one end of the billet with an extrusion die to form an extruded product. Methods for preparing an extruded product from a billet can also include providing a billet for extrusion; applying a simultaneous rotational shear and axial extrusion force to the billet to plasticize the billet; extruding the plasticized billet with an extrusion die to form an extruded product; and artificially aging the extruded product for less than the ASTM recommended amount of time.