Devices and Methods for Performing Shear-Assisted Extrusion and Extrusion Processes
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.
1 : A method for preparing an extruded product from a solid billet, the method comprising:
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.
2 : The method of claim 1 further comprising heating the as-cast billet for less than 11 hours between about 200° C. and 490° C. prior to applying the simultaneous rotational shear and axial extrusion force.
3 : The method of claim 1 wherein the as-cast billet is maintained below 200° C. prior to extrusion.
4 : The method of claim 1 wherein the as-cast billet is maintained at or below room temperature prior to extrusion.
5 : The method of claim 2 wherein the heat is applied in steps at predefined temperatures for predefined durations of time.
6 : The method of claim 3 wherein a difference between two of the steps is about 260° C.
7 : The method of claim 3 wherein a difference between two of the steps is about 30° C.
8 : The method of claim 1 wherein the as-cast billet is not homogenized prior to applying the simultaneous rotational shear and axial extrusion force to the as-cast billet.
9 : The method of claim 1 wherein the as-cast billet is not stress relieved and/or phase converted prior to extrusion.
10 : The method of claim 1 wherein the as-cast billet includes intermetallic and distinct microstructures.
11 : A method for preparing an extruded product from a billet, the method comprising:
providing a billet for extrusion;
while maintaining a majority of the billet below 100° C. prior to extrusion, 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.
12 : The method of claim 11 further comprising applying the simultaneous rotational shear and axial extrusion force to heat the one end of the billet.
13 : The method of claim 11 wherein the billet is an as-cast billet.
14 : The method of claim 11 wherein an opposing end of the billet is less than 100° C. prior to extrusion.
15 : The method of claim 11 wherein an opposing end of the billet is maintained about ambient temperature prior to extrusion.
16 : The method of claim 11 without billet pre-heating prior to starting the extrusion process
17 : The method of claim 11 wherein the billet is heated during plasticizing.
18 : A method for preparing an extruded product from a billet, the method comprising:
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 10 hrs.
19 : The method of claim 18 further comprising solution heat treating the extruded product prior to artificially aging the extruded product.
20 : The method of claim 19 wherein the solution heat treating comprises flash annealing for less than 1 hour at a temperature below 600° C.
21 : The method of claim 18 wherein the flash annealing comprises heating the extrudate in a furnace for less than the standard specifications and rapidly quenching to prevent any precipitation.
22 : The method of claim 18 further comprising artificially aging the extruded product for less than 10 hours.
23 : The method of claim 18 wherein the extruded product is heated to at least 200° C. during the artificial aging.