Processes and/or machines for producing continuous plastic deformation, and/or compositions and/or manufactures produced thereby
Certain exemplary embodiments can provide a manufacturing method, process, machine, and/or system for continuously consolidating granular materials, creating new alloys and/or composites, and/or modifying and/or refining material microstructure, by using plastic deformation of feedstock(s) provided in various structural forms. Materials produced during this process can be fabricated directly and/or in forms such as, e.g., wires, rods, tubes, sheets, plate and/or channels, etc.
1. A method for producing an extruded material from one or more feedstocks, the method comprising performing the activities of:
feeding a solid-state first feedstock selected from the one or more feedstocks through a first feedport and into a cavity defined between a rotor and an inner wall of a stationary container;
upon contacting the first feedstock with the rotor, creating a stirred material within the cavity via activities comprising plastically deforming the first feedstock;
via a container protrusion, wiping a portion of the stirred material from the rotor; and
continuously extruding the stirred material from the cavity through a die to generate an extruded material;
wherein:
the rotor defines a rotational axis about which the rotor is configured to operatively rotate;
the rotor defines a contained portion that operatively remains within the container;
the first feedstock is fed through the first feedport while the contained portion of the rotor is operatively rotating;
the contained portion has a generally conical frustum shape that defines a proximal end and a distal end, the proximal end located closer to a driven portion of the rotor than the distal end;
while the contained portion is operatively rotating:
a magnitude of an axial gap continuously changes across time, the axial gap measured along a first line extending in a predetermined perpetual cross-sectional plane that includes the rotational axis, the first line extending parallel to the rotational axis, the gap being the shortest distance, on the predetermined perpetual cross-sectional plane and along the first line, between (a) the exterior surface of the rotor and (b) a second line that extends in the predetermined perpetual cross-sectional plane, is perpendicular to the rotational axis, and intersects a centroid of an exit of the first feedport; and
a magnitude of a radial gap continuously changes across time, the radial gap measured along the second line and being the shortest distance, on the predetermined perpetual cross-sectional plane and along the second line, between the exterior of the rotor and the first line; and
as viewed along the rotational axis from the distal end, a visible proximal perimeter of the rotor located proximal from the distal end is greater than a visible distal perimeter of the rotor located at the distal end.
2. The method of claim 1 , wherein:
the wiping of the portion of the stirred material from the rotor occurs during the feeding of the first feedstock into the cavity.
3. The method of claim 1 , further comprising:
during the feeding of the first feedstock into the cavity, feeding a second feedstock selected from the one or more feedstocks through a second feedport and into the cavity.
4. The method of claim 1 , further comprising:
during the feeding of the first feedstock into the cavity, feeding a second feedstock selected from the one or more feedstocks through a second feedport and into the cavity; and
incorporating the second feedstock into the stirred material.
5. The method of claim 1 , further comprising:
during the feeding of the first feedstock into the cavity, feeding a second feedstock selected from the one or more feedstocks through a second feedport and into the cavity;
dividing the second feedstock; and
incorporating the second feedstock into the stirred material.
6. The method of claim 1 , further comprising:
during the feeding of the first feedstock into the cavity, feeding a second feedstock selected from the one or more feedstocks through a second feedport and into the cavity; and
within the cavity, reacting the second feedstock with the first feedstock.
7. The method of claim 1 , further comprising:
metallurgically and seamlessly bonding or consolidating the stirred material within the cavity.
8. The method of claim 1 , further comprising:
causing the stirred material to undergo melting, segregation, partitioning, or precipitation.
9. The method of claim 1 , further comprising:
depositing the extruded material onto a substrate.
10. The method of claim 1 , further comprising:
during the plastically deforming activity, alloying the first feedstock with a second feedstock selected from the one or more feedstocks.
11. The method of claim 1 , wherein:
said feeding activity occurs continuously.
12. The method of claim 1 , wherein:
said feeding activity occurs cyclically.
13. The method of claim 1 , wherein:
said extruding activity comprises back-extruding the extruded material through the rotor.
14. The method of claim 1 , wherein:
the rotor does not operatively effect the activity of feeding the first feedstock when the contained portion operatively translates along the rotational axis.
15. The method of claim 1 , wherein:
the rotor is configured to operatively change the volume of the cavity while the rotor is operatively translating along the rotational axis of the rotor.
16. The method of claim 1 , wherein:
the rotor defines one or more fins, flutes, flats, slots, steps, stepped spirals, nubs, buttons, cutting edges, and/or protrusions.
17. The method of claim 1 , wherein:
the container defines one or more fins, flutes, flats, slots, steps, stepped spirals, nubs, buttons, cutting edges, and/or protrusions.
18. The method of claim 1 , wherein:
the first feedstock enters the cavity in direction non-parallel to the rotational axis.
19. The method of claim 1 , wherein:
the extruded material is extruded through the die in direction non-parallel to the rotational axis.
20. The method of claim 1 , wherein:
the rotor and the die are configured to cooperatively impose an elongated form onto the extruded material, the elongated form having an annular shape.
21. The method of claim 1 , wherein:
a composition of the extruded material varies along a longitudinal axis of the extruded material.
22. The method of claim 1 , wherein:
at least one feedstock from the one or more feedstocks is in the form of particulates, powder, granules, machined chips, and/or swarfs.
23. The method of claim 1 , wherein:
at least one feedstock from the one or more feedstocks comprises a metal, alloy, ceramic, polymer, or glass.
24. The method of claim 1 , wherein:
the extruded material has the form of a pipe or tube filled with a material other than the extruded material.
25. The method of claim 1 , wherein:
the extruded material comprises a pure metal, an alloy, and/or a composite.
26. The method of claim 1 , wherein:
the extruded material has a microstructure defined by substantially uniform distribution of grain structure and one or more secondary phases.
27. The method of claim 1 , wherein:
the die is integral to the container.
28. The method of claim 1 , wherein:
the die is non-integral to the container.
29. The method of claim 1 , wherein:
the container is operatively fixed to a platform and/or frame.
30. The method of claim 1 , wherein:
the container defines one or more cavity-facing and/or externally-facing stirred material flow control features.
31. The method of claim 1 , wherein:
the rotor defines one or more stirred material flow control features.
32. The method of claim 1 , wherein:
the activities are performed in an inert atmosphere.
33. The method of claim 1 , further comprising:
forming a 3D printed component from the extruded material.
34. The method of claim 1 , further comprising:
depositing extruded material onto a substrate to form deposited material.
35. The method of claim 1 , further comprising:
deforming the substrate or previously deposited material via movement of the rotor and/or extruded material.
36. The method of claim 1 , further comprising:
heating the substrate or previously deposited material via movement of the rotor and/or extruded material.
37. The method of claim 1 , further comprising:
creating metallurgical bonding between the extruded material and a substrate.
38. The method of claim 1 , further comprising:
creating bonding between the extruded material and a substrate.
39. The method of claim 1 , further comprising:
creating bonding between the extruded material and a previously extruded material.
40. The method of claim 1 , further comprising:
creating metallurgical bonding between the extruded material and previously extruded material.
41. The method of claim 1 , further comprising:
creating bonding between the extruded material and previously extruded material.
42. The method of claim 1 , further comprising:
cooling the rotor, container, and/or extruded material.
43. The method of claim 1 , further comprising:
heating the rotor, container, and/or extruded material.
44. The method of claim 1 , further comprising:
recovering heat energy dissipated through the rotor and/or container.
45. A method for producing an extruded material from one or more feedstocks, the method comprising performing the activities of:
feeding a deformable solid-state first feedstock selected from the one or more feedstocks through a first feedport and into a cavity defined between a rotor and an inner wall of a stationary container;
upon contacting the first feedstock with the rotor, creating a stirred material within the cavity via activities comprising plastically deforming the first feedstock;
via a container protrusion, wiping a portion of the stirred material from the rotor; and
continuously extruding the stirred material from the cavity through a die to generate an extruded material;
wherein:
the rotor defines a rotational axis about which the rotor is configured to operatively rotate;
the rotor defines a contained portion that operatively remains within the container;
the first feedstock is fed through the stationary first feedport while the contained portion of the rotor is operatively rotating;
the contained portion has a generally conical frustum shape that defines a proximal end and a distal end, the proximal end located closer to a driven portion of the rotor than the distal end;
while the contained portion is operatively rotating:
a magnitude of an axial gap continuously changes across time, the axial gap measured along a first line extending in a predetermined perpetual cross-sectional plane that includes the rotational axis, the first line extending parallel to the rotational axis, the gap being the shortest distance, on the predetermined perpetual cross-sectional plane and along the first line, between (a) the exterior surface of the rotor and (b) a second line that extends in the predetermined perpetual cross-sectional plane, is perpendicular to the rotational axis, and intersects a centroid of an exit of the first feedport; or
a magnitude of a radial gap continuously changes across time, the radial gap measured along the second line and being the shortest distance, on the predetermined perpetual cross-sectional plane and along the second line, between the exterior of the rotor and the first line; and
as viewed along the rotational axis from the distal end, a visible proximal perimeter of the rotor located proximal from the distal end is greater than a visible distal perimeter of the rotor located at the distal end.
46. A method for producing an extruded material from one or more feedstocks, the method comprising performing the activities of:
feeding a deformable solid-state first feedstock selected from the one or more feedstocks through a first feedport and into a cavity defined between a rotor and an inner wall of a stationary container;
upon contacting the first feedstock with the rotor, creating a stirred material within the cavity via activities comprising plastically deforming the first feedstock;
via a container protrusion, wiping a portion of the stirred material from the rotor; and
continuously extruding the stirred material from the cavity through one or more dies to generate an extruded material;
wherein:
the rotor defines a rotational axis about which the rotor operatively rotates and along which the rotor is operatively translates;
a contained portion of the rotor is configured to operatively remain within the container while operatively translating along the rotational axis;
the first feedstock is fed through the first feedport while the contained portion is operatively rotating about the rotational axis and/or translating along to the rotational axis;
the rotor defines a semi-contained portion located immediately adjacent to the contained portion;
the rotor defines a contained perimeter located in a plane that is oriented perpendicularly to the rotational axis and that separates the contained portion from the semi-contained portion;
the semi-contained portion operatively enters and exits the container;
the feeding activity is operatively halted when the semi-contained portion begins entering the container;
the contained portion has a generally conical frustum shape that defines a proximal end and a distal end, the proximal end located closer to a driven portion of the rotor than the distal end;
while the contained portion is operatively rotating about the rotational axis and operatively translating along the rotational axis:
a magnitude of an axial gap continuously changes across time, the axial gap measured along a first line extending in a predetermined perpetual cross-sectional plane that includes the rotational axis, the first line extending parallel to the rotational axis, the gap being the shortest distance, on the predetermined perpetual cross-sectional plane and along the first line, between (a) the exterior surface of the rotor and (b) a second line that extends in the predetermined perpetual cross-sectional plane, is perpendicular to the rotational axis, and intersects a centroid of an exit of the first feedport; and/or
a magnitude of a radial gap continuously changes across time, the radial gap measured along the second line and being the shortest distance, on the predetermined perpetual cross-sectional plane and along the second line, between the exterior of the rotor and the first line; and
as viewed along the rotational axis from the distal end, a visible proximal perimeter of the rotor located proximal from the distal end is greater than a visible distal perimeter of the rotor located at the distal end.
47. A method for producing an extruded material from one or more feedstocks, the method comprising performing the activities of:
feeding a deformable solid-state first feedstock selected from the one or more feedstocks through a first feedport and into a cavity defined between a rotor and an inner wall of a stationary container;
upon contacting the first feedstock with the rotor, creating a stirred material within the cavity via activities comprising plastically deforming the first feedstock;
via a container protrusion, wiping a portion of the stirred material from the rotor; and
continuously extruding the stirred material from the cavity through one or more dies to generate an extruded material;
wherein:
the rotor defines a rotational axis about which the rotor is configured to operatively rotate and/or along which the rotor is configured to operatively translate;
a contained portion of the rotor is configured to operatively remain within the container while operatively translating along the rotational axis;
the first feedstock is fed through the first feedport while the contained portion is operatively rotating about the rotational axis and/or operatively translating along the rotational axis;
the rotor defines a semi-contained portion located immediately adjacent to the contained portion;
the rotor defines a contained perimeter located in a plane that is oriented perpendicularly to the rotational axis and that separates the contained portion from the semi-contained portion;
the semi-contained portion operatively enters and exits the container;
the feeding activity is operatively halted when the semi-contained portion begins entering the container;
the contained portion has a generally conical frustum shape that defines a proximal end and a distal end, the proximal end located closer to a driven portion of the rotor than the distal end;
while the contained portion is operatively translating:
a magnitude of an axial gap continuously changes across time, the axial gap measured along a first line extending in a predetermined perpetual cross-sectional plane that includes the rotational axis, the first line extending parallel to the rotational axis, the gap being the shortest distance, on the predetermined perpetual cross-sectional plane and along the first line, between (a) the exterior surface of the rotor and (b) a second line that extends in the predetermined perpetual cross-sectional plane, is perpendicular to the rotational axis, and intersects a centroid of an exit of the first feedport; and/or
a magnitude of a radial gap continuously changes across time, the radial gap measured along the second line and being the shortest distance, on the predetermined perpetual cross-sectional plane and along the second line, between the exterior of the rotor and the first line; and
as viewed along the rotational axis from the distal end, a visible proximal perimeter of the rotor located proximal from the distal end is greater than a visible distal perimeter of the rotor located at the distal end.
48. A machine configured for producing an extruded material from one or more feedstocks, the machine comprising:
a feedstock feeder that operatively feeds a deformable solid-state first feedstock selected from the one or more feedstocks through a first feedport and into a cavity defined between a rotating rotor and an inner wall of a stationary container;
a rotor that, upon contacting the first feedstock with the rotor operatively creates a stirred material within the cavity via activities comprising plastically deforming the first feedstock; and
a container protrusion that operatively wipes a portion of the unmelted stirred material from the rotor;
wherein:
the rotor defines a rotational axis about which the rotor is configured to operatively rotate and/or along which the rotor is configured to operatively translate;
a contained portion of the rotor is configured to operatively remain within the container while operatively translating along the rotational axis;
the first feedstock is fed through the first feedport while the contained portion is operatively rotating about the rotational axis and/or translating along the rotational axis;
the rotor defines a semi-contained portion located immediately adjacent to the contained portion;
the rotor defines a contained perimeter located in a plane that is oriented perpendicularly to the rotational axis and that separates the contained portion from the semi-contained portion;
the semi-contained portion operatively enters and exits the container;
the machine operatively halts feeding the first feedstock when the semi-contained portion begins entering the container;
the contained perimeter is greater than a terminal perimeter located at a non-driven terminal end of the rotor;
the rotor has a generally conical frustum shape;
while the contained portion is operatively rotating about the rotational axis and/or translating along the rotational axis:
a magnitude of an axial gap continuously changes across time, the axial gap measured along a first line extending in a predetermined perpetual cross-sectional plane that includes the rotational axis, the first line extending parallel to the rotational axis, the gap being the shortest distance, on the predetermined perpetual cross-sectional plane and along the first line, between (a) the exterior surface of the rotor and (b) a second line that extends in the predetermined perpetual cross-sectional plane, is perpendicular to the rotational axis, and intersects a centroid of an exit of the first feedport; and/or
a magnitude of a radial gap continuously changes across time, the radial gap measured along the second line and being the shortest distance, on the predetermined perpetual cross-sectional plane and along the second line, between the exterior of the rotor and the first line;
as viewed along the rotational axis from the distal end, a visible proximal perimeter of the rotor located proximal from the distal end is greater than a visible distal perimeter of the rotor located at the distal end; and
while the first feedstock is plastically deformed, a microstructure of the first feedstock is changed.
49. The machine of claim 48 , further comprising:
a translatable feeder frame connected to the container and configured to operatively feed a predetermined quantity of one or more of feedstocks through the first feedport and into the cavity.
50. The machine of claim 48 , further comprising:
a 3D printing bed that operatively translates into a predetermined relative position with respect to the one or more dies.
51. The machine of claim 48 , further comprising:
one or more cooling passages extending within the rotor and/or the container.
52. The machine of claim 48 , wherein:
the rotor is operably attached to a rotary spindle of a machine tool.