Dual-phase hot extrusion of metals

1. A method of dual-phase hot metal extrusion comprising the steps of:

a) providing a load carrier made of a first metal material, wherein the load carrier comprises a load end, a blind end, and at least one load chamber having a depth extending axially from the load end towards the blind end, wherein the at least one load chamber comprises a load material and a void space, wherein the load material comprises a second metal material, the second metal material having a lower melting point than the melting point of the first metal material, and wherein the void space is configured to accommodate at least a portion of the second metal material in its molten form when the load carrier is heated;

b) heating the load carrier to a temperature above the melting point of the second metal material but below the melting point of the first metal material to form a solid load carrier comprising a liquid metal in the at least one load chamber;

c) providing an extrusion tool comprising a first extrusion die, a second extrusion die, and a cooling cavity, wherein an extrusion transfer channel extends from the first extrusion die through the cooling cavity to the second extrusion die of the extrusion tool, wherein a portion of the extrusion transfer channel extending through the cooling cavity comprises at least one opening located between the first extrusion die and the second extrusion die, and wherein the cooling cavity comprises at least one cooling port configured to provide a cooling agent at the at least one opening of the extrusion transfer channel;

d) providing a cooling agent through the at least one cooling port; and

e) extruding the heated load carrier through the extrusion tool to provide an extruded product having modified thermal conductivity, electrical conductivity, or tensile properties.

2. The method of claim 1 , wherein the portion of the extrusion transfer channel of the extrusion tool extending through the cooling cavity comprises at least two openings located between the first extrusion die and the second extrusion die.

3. The method of claim 2 , wherein the cooling cavity of the extrusion tool comprises at least two cooling ports configured to provide the cooling agent at the at least two openings of the extrusion transfer channel.

4. The method of claim 1 , wherein the portion of the extrusion transfer channel of the extrusion tool extending through the cooling cavity comprises at least three openings located between the first extrusion die and the second extrusion die.

5. The method of claim 4 , wherein the cooling cavity of the extrusion tool comprises at least three cooling ports configured to provide the cooling agent at the at least three openings of the extrusion transfer channel.

6. The method of claim 1 , wherein the portion of the extrusion transfer channel of the extrusion tool extending through the cooling cavity comprises at least four openings located between the first extrusion die and the second extrusion die.

7. The method of claim 6 , wherein the cooling cavity of the extrusion tool comprises at least four cooling ports configured to provide the cooling agent at the at least four openings of the extrusion transfer channel.

8. The method of claim 1 , wherein the cooling agent is water.

9. The method of claim 1 , wherein the load carrier comprises at least five load chambers.

10. The method of claim 9 , wherein the first metal material comprises copper and the second metal material comprises magnesium, aluminum, antimony, tin, zinc, or any combination thereof.

11. The method of claim 1 , wherein the first metal material comprises copper and the second metal material comprises magnesium, aluminum, antimony, tin, zinc, or any combination thereof.

12. The method of claim 1 , further comprising the steps of:

f) providing a second load carrier made of the first metal material, wherein the second load carrier comprises a load end, a blind end, and at least one load chamber having a depth extending axially from the load end towards the blind end, wherein the at least one load chamber comprises a second load material, wherein the second load material is the extruded product formed in step e);

g) heating the second load carrier to a temperature suitable for melting the second metal material in the extruded product and suitable for extruding the second load carrier; and

h) extruding the second load carrier to provide a second extruded product.

13. The method of claim 12 , wherein the second load carrier is extruded through the extrusion tool provided in step c).

14. A method of dual-phase hot metal extrusion comprising the steps of:

a) providing a load carrier made of a first metal material, wherein the load carrier comprises a load end, a blind end, and at least one load chamber having a depth extending axially from the load end towards the blind end, wherein the at least one load chamber comprises a load material and a void space, wherein the load material comprises a second metal material, the second metal material having a lower melting point than the melting point of the first metal material, and wherein the void space is configured to accommodate at least a portion of the second metal material in its molten form when the load carrier is heated;

b) heating the load carrier to a temperature above the melting point of the second metal material but below the melting point of the first metal material to form a solid load carrier comprising a liquid metal in the at least one load chamber;

c) providing an extrusion tool comprising a first extrusion die, a second extrusion die, and a cooling cavity, wherein an extrusion transfer channel extends from the first extrusion die through the cooling cavity to the second extrusion die of the extrusion tool, wherein a portion of the extrusion transfer channel extending through the cooling cavity comprises at least one opening located between the first extrusion die and the second extrusion die, and wherein the cooling cavity comprises at least one cooling port configured to provide a cooling agent at the at least one opening of the extrusion transfer channel;

d) providing a cooling agent through the at least one cooling port; and

e) continuously extruding the heated load carrier, wherein the load carrier is extruded through the first extrusion die, contacted with water, and extruded through the second extrusion die inside the container of an extrusion press.

15. The method of claim 14 , wherein the load carrier comprises at least three load chambers.

16. The method of claim 14 , wherein the load carrier comprises at least four load chambers.

17. The method of claim 14 , wherein the load carrier comprises at least five load chambers.

18. The method of claim 14 , wherein the load carrier comprises copper.

19. The method of claim 14 , wherein the cooling cavity comprises at least two cooling ports.

20. The method of claim 14 , wherein the cooling cavity comprises at least three cooling ports.