Method for Forming Hollow Profile Non-Circular Extrusions Using Shear Assisted Processing and Extrusion (ShAPE)

Abstract

A process for forming extruded products using a device having a scroll face configured to apply a rotational shearing force and an axial extrusion force to the same preselected location on material wherein a combination of the rotational shearing force and the axial extrusion force upon the same location cause a portion of the material to plasticize, flow and recombine in desired configurations. This process provides for a significant number of advantages and industrial applications, including but not limited to extruding tubes used for vehicle components with 50 to 100 percent greater ductility and energy absorption over conventional extrusion technologies, while dramatically reducing manufacturing costs.

What is claimed is: 
     
         1 . A system for shear-assisted extrusion, the system comprising:
 a container for a feedstock material;   a die having a scroll face with a plurality of spiral grooves defined therein, the die configured to engage feedstock material that is rotated relative to the die;   a ram configured to establish an axial extrusion force simultaneously with rotation of the feedstock material;   wherein the axial extrusion force and the rotation plasticize the feedstock material against the scroll face;   wherein the plurality of spiral grooves of the die are configured to direct plasticized feedstock material from an interface between the feedstock material and the scroll face through an opening in the die within the scroll face;   wherein the scroll face is oriented generally perpendicular to a direction of the axial extrusion force; and   wherein the feedstock material comprises at least one of magnesium or aluminum.   
     
     
         2 . The system of  claim 1 , wherein the feedstock material comprises magnesium. 
     
     
         3 . The system of  claim 2 , wherein an extrudate formed from the plasticized feedstock material comprises a magnesium alloy or magnesium metal-matrix-composite (MMC). 
     
     
         4 . The system of  claim 3 , wherein the magnesium alloy or magnesium metal-matrix-composite (MMC) comprises aluminum. 
     
     
         5 . The system of  claim 3 , wherein the magnesium alloy comprises a magnesium rare earth metal alloy. 
     
     
         6 . The system of  claim 4 , wherein the magnesium alloy comprises a magnesium-silicon alloy. 
     
     
         7 . The system of  claim 1 , wherein feedstock material comprises aluminum. 
     
     
         8 . The system of  claim 7 , wherein an extrudate formed from the plasticized feedstock material comprises a comprises an aluminum alloy. 
     
     
         9 . The system of  claim 8 , wherein the aluminum alloy comprises an aluminum-manganese alloy. 
     
     
         10 . The system of  claim 1 , wherein the ram is configured to rotate. 
     
     
         11 . The system of  claim 1 , wherein the container is configured to rotate. 
     
     
         12 . The system of  claim 1 , wherein an extrudate formed from the plasticized feedstock material is homogenized by the axial extrusion force and the rotation, as compared to the feedstock material prior to the axial extrusion force and the rotation, without requiring a heat treatment post extrusion. 
     
     
         13 . A method for shear-assisted extrusion comprising:
 engaging a feedstock material in a container using a die having a scroll face with a plurality of spiral grooves defined therein;   rotating the feedstock material relative to the die;   simultaneously applying an axial extrusion force with the rotation to plasticize the feedstock material against the scroll face; and   directing plasticized feedstock material from an interface between the feedstock material and the scroll face through an opening in the die using the plurality of spiral grooves;   wherein the scroll face is oriented generally perpendicular to a direction of the axial extrusion force; and   wherein the feedstock material comprises at least one of magnesium or aluminum.   
     
     
         14 . The method of  claim 13 , wherein the feedstock material comprises magnesium. 
     
     
         15 . The method of  claim 14 , wherein an extrudate formed from the plasticized feedstock material comprises a magnesium alloy or magnesium metal-matrix-composite (MMC). 
     
     
         16 . The method of  claim 15 , wherein the magnesium alloy or magnesium metal-matrix-composite (MMC) comprises aluminum. 
     
     
         17 . The method of  claim 13 , wherein the feedstock material comprises aluminum. 
     
     
         18 . The method of  claim 17 , wherein an extrudate formed from the plasticized feedstock material comprises an aluminum alloy. 
     
     
         19 . The method of  claim 18 , wherein the aluminum alloy comprises an aluminum-manganese alloy. 
     
     
         20 . The method of  claim 13 , wherein the method homogenizes the feedstock material during extrusion without requiring post-extrusion heat treatment.