Granted Patent B2

US 12,447,518 · App. 17/985,611 · Granted Oct 21, 2025

Inventors: Vineet V. Joshi (Richland, WA); Scott A. Whalen (West Richland, WA); Curt A. Lavender (Richland, WA); Glenn J. Grant (Benton City, WA); Md. Reza-E-Rabby (Richland, WA); Aashish Rohatgi (Richland, WA); Jens T. Darsell (West Richland, WA)

Assignee: Battelle Memorial Institute

B21C25/02B21C23/002B21C23/08B21C23/142B21C23/218B21C27/00B21C29/003B21C33/00B21C23/215B21C37/155B22F2003/208B22F2301/058C22C1/0408C22C1/0416C22C1/0425

Abstract

Claims (42)

1. A shear assisted extrusion process comprising;

providing both axial and rotational forces between feedstock material in a container comprising a die cavity and a scroll-faced-die to plasticize one end of the feedstock material and provide plasticized feedstock material through at least one opening in the scroll-faced-die and over a mandrel coupled to the scroll-faced-die to form a hollow extrudate,

wherein:

the feedstock material comprises crushed material fragments comprising chunks, powder, or flakes, or combinations thereof; and

a scroll-face of the scroll-faced-die defines spirals as channels or ridges upon the scroll-face to direct the plasticized feedstock material through the at least one opening in the scroll-faced-die;

wherein the scroll-face is oriented generally perpendicular to a direction of an axial force imparted by the scroll-faced-die against the feedstock material or vice versa.

2. The process of claim 1 , wherein the spirals have between 1 and 16 starts.

3. The process of claim 1 , wherein the at least one opening of the scroll-faced-die is contiguous with at least one channel of the scroll-face.

4. The process of claim 3 , wherein the at least one opening of the scroll-face is contiguous with at least two channels of the scroll-face.

5. The process of claim 3 , wherein the at least one opening of the scroll-faced-die comprises a plurality of openings.

6. The process of claim 5 , wherein each of the openings is contiguous with at least one channel.

7. The process of claim 5 , wherein the plasticized feedstock material extends through each of the openings and merges to form a single extrudate.

8. The process of claim 1 , wherein the crushed material fragments comprises crushed arc-melted alloy buttons.

9. The process of claim 8 , wherein the crushed arc-melted alloy buttons comprise aluminum, magnesium, titanium, copper, and iron.

10. The process of claim 1 , wherein the crushed material fragments comprises a high entropy alloy or precursor thereof.

11. The process of claim 1 , wherein crushed material fragments comprise at least one of copper, aluminum, magnesium, or combinations thereof.

12. The process of claim 11 , wherein the crushed material fragments are consolidated in response to the scroll-faced-die being rotated at 500 RPM under load control with a maximum load set at 85 MPa.

13. The process of claim 11 , wherein the crushed material fragments are consolidated in response to the scroll-faced-die being rotated at 500 RPM under load control with a maximum load set at 175 MPa.

14. A system for shear-assisted extrusion, the system comprising:

a container for a feedstock material;

a portal bridge die having a scroll face with a plurality of spiral grooves defined therein, the portal bridge die configured to be rotated relative to the feedstock material or vice versa;

a ram configured to establish an axial extrusion force simultaneously with rotation of the portal bridge die or the container;

wherein the axial extrusion force and the rotation plasticize the feedstock material against the scroll face; and

wherein the grooves of the portal bridge die are configured to direct plasticized feedstock material from a first location at an interface between the feedstock material and the scroll face through the die via multiple portals defined within the scroll face and over a mandrel of the portal bridge die to form a hollow extrudate;

wherein the scroll face is oriented generally perpendicular to a direction of the axial extrusion force.

15. The system of claim 14 , wherein the plasticized feedstock material separates into respective streams of material passing through the respective portals.

16. The system of claim 15 , wherein the respective streams of material recombine to form the hollow extrudate.

17. The system of claim 16 , wherein the hollow extrudate comprises a non-circular profile.

18. The system of claim 17 , wherein the non-circular profile is defined at least in part by the mandrel.

19. The system of claim 18 , wherein the portal bridge die defines the mandrel.

20. The system of claim 14 , wherein a respective portal in the scroll face is contiguous with grooves of the scroll face.

21. The system of claim 14 , wherein the scroll face defines a first groove having a first orientation to direct material radially outward from a center of the scroll face toward a respective portal, and a second groove having an opposite second orientation to direct material radially inward toward a center of the scroll face from a periphery, toward the respective portal.

22. The system of claim 14 , wherein the feedstock material comprises at least one of copper, aluminum, magnesium, or combinations thereof.

23. The system of claim 22 , wherein the feedstock material comprises an alloy.

24. The system of claim 22 , wherein the feedstock material comprises a magnesium alloy in billet form;

wherein the ram is configured to establish the axial extrusion force at or below 25 MPa; and

wherein the system is configured to control the rotation and axial extrusion force to maintain a temperature of the plasticized material less than 100° C.

25. The system of claim 14 , wherein the feedstock material comprises crushed material fragments comprising chunks, powder, or flakes, or combinations thereof.

26. The system of claim 14 , wherein the feedstock material comprises precursor materials for a high entropy alloy; and

wherein the plasticized material forms a high entropy alloy extrudate.

27. The system of claim 14 , wherein the feedstock material comprises crushed arc-melted alloy buttons.

28. The system of claim 14 , wherein the container is configured to rotate relative to the portal bridge die.

Assignments (1)

Continuity (9)

References Cited (313)