Shear-Assisted Extrusion for Conductive Metal Composite Profiles
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Solution Overview
Problem
There is a need for technologies that can introduce additives into metals to enhance electrical performance, such as higher electrical conductivity and current density, without compromising mechanical properties or increasing impurities.
Innovation Solution
The development of a multi-axis shear-assisted extrusion machine that allows for the introduction of additives into metals during the extrusion process, enabling the production of alloys or composites with improved electrical performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If additives are introduced into metals to enhance electrical performance, then electrical conductivity is improved, but mechanical properties may be compromised
Solution Approach 1:
The patent applies parameter changes by precisely controlling the composition, size, and distribution of additive particles during the extrusion process. By adjusting parameters such as particle diameter (0.1-10 micrometers), concentration (0.1-10 wt%), and extrusion temperature, the patent optimizes both electrical conductivity and mechanical strength simultaneously, resolving the contradiction between these two properties.
Solution Approach 2:
The patent creates composite metal materials by incorporating conductive additives (such as copper, silver, or graphite particles) into metal matrices through extrusion. This composite structure combines the mechanical strength of the metal matrix with the high electrical conductivity of the additive particles, thereby improving electrical performance without sacrificing mechanical properties.
2Ease of manufacture
If traditional extrusion processes are used, then manufacturing simplicity is maintained, but processing time and energy consumption are high
Solution Approach 1:
The patent applies preliminary action by pre-mixing the metal matrix and additive particles in specific proportions before the extrusion process. This pre-preparation of homogeneous mixtures ensures that additives are uniformly distributed throughout the final product, eliminating the need for complex post-processing steps and reducing overall processing time while maintaining manufacturing simplicity.
Solution Approach 2:
The patent implements continuous extrusion processing where the metal matrix and additives are continuously fed, mixed, and formed into final products in a single uninterrupted operation. This continuous process eliminates idle time between steps, maintains steady-state processing conditions, and significantly reduces total processing time compared to batch processing methods.
3Manufacturing precision
If high pressure and temperature are applied during extrusion, then material flow and shaping are improved, but energy consumption increases
Solution Approach 1:
The patent optimizes extrusion parameters by conducting the process at moderate temperatures (0.5-2.0 times the melting point of the base metal) and pressures sufficient to achieve complete densification. By carefully selecting and controlling these parameters, the patent achieves high shaping quality and full density without excessive energy input, resolving the contradiction between manufacturing precision and energy consumption.
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 approach enables the extrusion of metal wires, bars, or tubes with improved mechanical properties and enhanced electrical conductivity, reducing energy consumption and processing time while maintaining the integrity of the metal substrates.
Implementation Method 1
the rear spindle rotatable with respect to the rear movable headstock and the die tool to generate, together with the front spindle and the feedstock material, a rotation-induced shear force between the feedstock material and the die tool
Implementation Method 2
a ram connected to the third tooling plate and configured to generate an axial extrusion force
Data Source
AI summary
A system for performing shear-assisted extrusion can include a front fixed endstock and a rear fixed endstock. The system can include a front movable headstock and a rear movable headstock. The system can include a die tool connected to the front fixed endstock. The die tool can include a face configured to engage and plasticize a face of feedstock material. The die tool can define an opening to receive plasticized feedstock material therethrough. The system can include a front spindle supported by the front movable headstock. The front spindle can be rotatable to rotate the feedstock material with respect to the front movable headstock. The system can include a rear spindle connected to the rear movable headstock, the rear spindle rotatable with respect to the rear movable headstock and the die tool.