Devices and Methods for Performing Shear-Assisted Extrusion and Extrusion Processes

Abstract

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.