Granted Patent B2

US 12,365,027 · App. 17/473,178 · Granted Jul 22, 2025

Inventors: Scott A. Whalen (West Richland, WA); Jens T. Darsell (West Richland, WA); Md. Reza-E-Rabby (Richland, WA); Brandon Scott Taysom (West Richland, WA); Tianhao Wang (Richland, WA); Darrell R. Herling (Kennewick, WA); Xiao Li (Richland, WA)

Assignee: Battelle Memorial Institute

B22F3/20B21C23/001B22F3/24B22F2003/248B22F2301/052B22F2302/25

Abstract

Claims (36)

1. A method for preparing extruded material by shear assisted processing and extrusion, the method comprising:

applying axial extrusion force and rotational force at an interface of a face of a die tool and a face of a metallic stock material provided in a rotating feedstock container to form an extruded material at a rate between 2 and 13 m/min, wherein:

the face of the die tool comprises at least a portion that is generally perpendicular to the axial extrusion force; and

the portion that is generally perpendicular to the axial extrusion force comprise at least one spiral groove that directs plasticized material of the stock material toward aperture ports of the face of the die tool; and

wherein the metallic stock material is not pre-heated before applying the axial extrusion force and the rotational shearing force.

2. The method of claim 1 wherein the metallic stock material is defined by castings.

3. The method of claim 1 wherein the metallic stock material comprises Al.

4. The method of claim 1 wherein the extruded material comprises Al.

5. The method of claim 1 wherein the method further comprises maintaining a temperature of the die face below 420° C.

6. The method of claim 1 wherein the extruded material has a tensile strength between 500 and 580 MPa.

7. The method of claim 1 wherein the extruded material has a yield strength between 420 and 500 MPa.

8. The method of claim 1 wherein the extruded material has an elongation % between 12 and 18.

9. The method of claim 1 wherein the rate is between 3 and 13 m/min.

10. The method of claim 1 wherein the rate is between 7 and 13 m/min.

11. The method of claim 1 , wherein the metallic stock material is a non-homogenized metallic billet.

12. The method of claim 11 , wherein at least a portion of the extruded material is homogenized due to the applying of the axial extrusion force and the rotational shearing force.

13. A method for shear-assisted extrusion, the method comprising:

establishing an axial extrusion force and a rotational shearing force at an interface of a face of a die tool and a face of a non-homogenized metallic billet provided in a rotating feedstock container, wherein:

the face of the die tool comprises at least a portion that is generally perpendicular to the axial extrusion force; and

the portion that is generally perpendicular to the axial extrusion force comprises a spiral groove;

directing plasticized material of the non-homogenized metallic billet toward aperture ports of the face of the die tool using the spiral groove; and

extruding an extruded material from the non-homogenized metallic billet at a rate between 2 and 13 m/min.

14. The method of claim 13 , wherein the non-homogenized metallic billet is not pre-heated before applying the axial extrusion force and the rotational shearing force.

15. The method of claim 13 , wherein the non-homogenized metallic billet is not pre-heated or homogenized to remove microfissures before establishing the axial extrusion force and the rotational shearing force.

16. The method of claim 13 , wherein the extruded material is extruded at a rate between 3 and 13 m/min.

17. The method of claim 13 , wherein a linear speed of the non-homogenized metallic billet or the die tool is 0.36 m/min.

18. The method of claim 17 , wherein the linear speed of 0.36 m/min causes a rate of extrusion of between 7 and 8 m/min.

19. A method for shear-assisted extrusion, the method comprising:

establishing an axial extrusion force and a rotational shearing force at an interface of a face of a die tool and a face of a non-homogenized metallic billet provided in a rotating feedstock container; and

extruding an extruded material from the non-homogenized metallic billet at a rate between 2 and 13 m/min;

wherein:

the face of the die tool comprises at least a portion that is generally perpendicular to the axial extrusion force;

the portion that is generally perpendicular to the axial extrusion force comprises a spiral groove that directs plasticized material of the non-homogenous metallic billet toward aperture ports of the face of the die tool;

the non-homogenized metallic billet is not pre-heated before establishing the axial extrusion force and the rotational shearing force; and

the non-homogenized metallic billet is not homogenized to remove microfissures before establishing the axial extrusion force and the rotational shearing force.

20. The method of claim 19 , wherein the non-homogenized metallic billet is not pre-heated or homogenized to cause phase conversion and has less uniform consistency before extrusion than the extruded material.

Assignments (2)

Continuity (13)

References Cited (261)