Extrusion processes for forming extrusions of a desired composition from a feedstock

Whalen, Scott A.; Joshi, Vineet V.; Reza-E-Rabby, Md.; Darsell, Jens T.; Komarasamy, Mageshwari; Lavender, Curt A.; Grant, Glenn J.; Rohatgi, Aashish; Frazier, William E.

Title: Extrusion processes for forming extrusions of a desired composition from a feedstock

Abstract

Devices and methods for performing shear-assisted extrusion processes for forming extrusions of a desired composition from a feedstock material are provided. The processes can use a device having a scroll face having an inner diameter portion bounded by an outer diameter portion, and a member extending from the inner diameter portion beyond a surface of the outer diameter portion.Extrusion feedstocks and extrusion processes are provided for forming extrusions of a desired composition from a feedstock. The processes can include providing a feedstock having at least two different materials and engaging the materials with one another within a feedstock container.Methods for preparing metal sheets are provided that can include preparing a metal tube via shear assisted processing and extrusion; opening the metal tube to form a sheet having a first thickness; and rolling the sheet to a second thickness that is less than the first thickness.

Inventors:: Whalen, Scott A.; Joshi, Vineet V.; Reza-E-Rabby, Md.; Darsell, Jens T.; Komarasamy, Mageshwari; Lavender, Curt A.; Grant, Glenn J.; Rohatgi, Aashish; Frazier, III, William E.

Issue Date:: 2023-06-27

Research Org.:: Pacific Northwest National Laboratory (PNNL), Richland, WA (United States)

Sponsoring Org.:: USDOE

OSTI Identifier:: 1998523

Patent Number(s):: 11684959

Application Number:: 17/665,433

Assignee:: Battelle Memorial Institute (Richland, WA)

DOE Contract Number:: AC05-76RL01830

Resource Type:: Patent

Resource Relation:: Patent File Date: 02/04/2022

Country of Publication:: United States

Language:: English

Citation Formats


                    Whalen, Scott A., Joshi, Vineet V., Reza-E-Rabby, Md., Darsell, Jens T., Komarasamy, Mageshwari, Lavender, Curt A., Grant, Glenn J., Rohatgi, Aashish, and Frazier, III, William E. Extrusion processes for forming extrusions of a desired composition from a feedstock.  United States: N. p., 2023. 
        Web.

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                    Whalen, Scott A., Joshi, Vineet V., Reza-E-Rabby, Md., Darsell, Jens T., Komarasamy, Mageshwari, Lavender, Curt A., Grant, Glenn J., Rohatgi, Aashish, & Frazier, III, William E. Extrusion processes for forming extrusions of a desired composition from a feedstock.  United States.

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                    Whalen, Scott A., Joshi, Vineet V., Reza-E-Rabby, Md., Darsell, Jens T., Komarasamy, Mageshwari, Lavender, Curt A., Grant, Glenn J., Rohatgi, Aashish, and Frazier, III, William E. Tue .  
        "Extrusion processes for forming extrusions of a desired composition from a feedstock".  United States.  https://www.osti.gov/servlets/purl/1998523.

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@article{osti_1998523,

  title        = {Extrusion processes for forming extrusions of a desired composition from a feedstock},

  author       = {Whalen, Scott A. and Joshi, Vineet V. and Reza-E-Rabby, Md. and Darsell, Jens T. and Komarasamy, Mageshwari and Lavender, Curt A. and Grant, Glenn J. and Rohatgi, Aashish and Frazier, III, William E.},

  abstractNote = {Devices and methods for performing shear-assisted extrusion processes for forming extrusions of a desired composition from a feedstock material are provided. The processes can use a device having a scroll face having an inner diameter portion bounded by an outer diameter portion, and a member extending from the inner diameter portion beyond a surface of the outer diameter portion.Extrusion feedstocks and extrusion processes are provided for forming extrusions of a desired composition from a feedstock. The processes can include providing a feedstock having at least two different materials and engaging the materials with one another within a feedstock container.Methods for preparing metal sheets are provided that can include preparing a metal tube via shear assisted processing and extrusion; opening the metal tube to form a sheet having a first thickness; and rolling the sheet to a second thickness that is less than the first thickness.},

  doi          = {},

  journal      = {},
number       = ,

  volume       = ,

  place        = {United States},

  year         = {2023},

  month        = {6}

}

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Title: Extrusion processes for forming extrusions of a desired composition from a feedstock

Abstract

Citation Formats

Extrusion Press Die Assembly patent-application, April 2014

Multi-Material Component and Methods of Making Thereof patent-application, February 2018

Structure for joining members including a nut and an auxiliary member patent, August 2012

Systems and Methods for Joining Components patent-application, June 2016

Aluminum Alloy Extrudate Excellent In Bending Crush Resistance And Corrosion Resistance patent-application, July 2012

Hybrid disk-cone extrusion die assembly patent, October 2003

Friction Stir Extrusion of Nonweldable Materials for Downhole Tools patent-application, August 2017

Friction-Stir Extruders and Friction-Stir Extrusion Processes patent-application, March 2015

Joining Method patent-application, May 2017

High-Strength Aluminum Alloy Product And Method Of Producing The Same patent-application, March 2010

Mg-based alloy patent, November 2012

Friction Stir Welding System and Method patent-application, February 2008

Magnesium: Current and potential automotive applications journal, February 2002

Enhanced Friction-Stir-Welding Joint Strength Between Steel and Aluminum with Surface Coating and Preformed Local Texture patent-application, January 2017

Method for producing seamless hollow extruded products of aluminum alloy and die set therefor patent-application, March 2012

System and Process for Friction Consolidation Fabrication of Permanent Magnets and Other Extrusion and Non-Extrusion Structures patent-application, November 2014

Method for manufacturing permanent magnets patent, January 1989

Tool Temperature and Process Modeling of Friction Stir Welding journal, January 2018

Method of making bonded or sintered permanent magnets patent, November 1995

A preliminary study on the feasibility of friction stir back extrusion journal, May 2012

Method and apparatus for extrusion of tubing sheeting and profile shapes patent, October 1995

Extrusion Press Systems And Methods patent-application, April 2014

Friction Stir Weld Tool and Method patent-application, December 2016

Friction Stir Welding Tool And Friction Stir Welding Method patent-application, March 2009

Joined body and process for manufacturing the same patent-application, November 2009

Metal Joining Method and Metal Joined Member patent-application, June 2017

Method of making magnets by polymer-coating magnetic powder patent, January 1976

Aluminium-steel lap joining by multipass friction stir welding journal, September 2016

Method of making magnets patent, July 1975

Friction stir welding tool having a counterflow pin configuration patent-application, October 2008

Friction stirring interlocking of dissimilar materials patent, August 2019

Different-Material Joining Structure patent-application, December 2018

Method of making magnets patent, August 1976

Friction-Stir Joining Method patent-application, March 2014

Friction Stir Welding Method and Joined Body patent-application, August 2017

Apparatus for Extruding Cylindrical Magnets patent, February 1972

High ductility aluminum alloy made from powder by friction extrusion journal, June 2019

Compositions and methods for dissimilar material welding patent, April 2014

Extrusion Die for Forming Hollow Material patent-application, August 2016

Induction Motor Rotor and a Method of Manufacturing the Same patent-application, June 2017

Fabrication of High Performance Magnesium/Carbon-Fiber/PEEK Laminated Composites journal, January 2003

Apparatus for ultrasonically assisted melt extrusion of fibers patent, March 2000

Welded component patent, January 2008

Forming metallic composite materials by urging base materials together under shear patent, November 1993

Intermetallic compounds in Al 6016/IF-steel friction stir spot welds journal, June 2010

Method of plastic forming of materials patent, April 1998

Friction Spot Welding and Friction Seam Welding patent-application, December 2015

Friction Stir Welding Tool and Process For Welding Dissimilar Materials patent-application, December 2011

Microstructure and mechanical properties of equimolar FeCoCrNi high entropy alloy prepared via powder extrusion journal, August 2016

Aluminium powder metallurgy technology for high-strength applications journal, June 1981

Anisotropic nanocomposite rare earth permanent magnets and method of making patent-application, January 2006

Aluminum alloy products and methods of preparation patent, November 1976

Method of friction stir welding dissimilar metals and workpiece assemblies formed thereby patent-application, May 2011

Method for Low-Temperature Joining of Metal Materials, and Joint Structure patent-application, July 2021

Equal-Channel Angular Extrusion of a Low-Density High-Entropy Alloy Produced by High-Energy Cryogenic Mechanical Alloying journal, September 2014

Densification of Thermal Spray Coatings patent-application, December 2004

Method for Forming Hollow Profile Non-circular Extrusions Using Shear Assisted Processing and Extrusion (Shape) patent-application, November 2018

Method for Operating Double-Action Friction Stir Welding Device, and Double-Action Friction Stir Welding Device patent-application, March 2021

Joining of polymers and polymer-metal hybrid structures: Recent developments and trends journal, August 2009

Extrusion of a Metal Alloy Containing Copper and Zinc patent-application, August 2008

Controlled Speed Friction Stir Tool Probe Bodies Having Non-Linear, Continuous, Monotonically-Decreasing Curved Axial Profiles and Integrated Surface Features patent-application, January 2016

Tool, apparatus, and method for welding workpieces patent, January 2008

Shear-extrusion method patent, August 2006

Method of Making Permanent Magnets patent, May 1972

Composite Preform having a Controlled Fraction of Porosity in at Least one Layer and Methods for Manufacture and Use patent-application, October 2009

Method of Joining Metallic Materials patent-application, March 2004

Method and apparatus for extruding powdered material patent, August 1995

In-Situ Interlocking of Metals Using Additive Friction Stir Processing patent-application, June 2016

Joining of dissimilar materials journal, January 2015

Solid State Joining Using Additive Friction Stir Processing patent-application, June 2016

Friction stir welding tool having a scroll-free concentric region patent, September 2011

Tapered extrusion die and method of forming the same patent, September 1981

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Method of Bonding Dissimilar Metal Materials and Bonded Body of Dissimilar Metal Materials patent-application, March 2012

Method and apparatus for forming elongated articles having reduced diameter cross-sections patent, November 1981

Nanocomposite Permanent Magnets And Methods Of Making The Same patent-application, January 2014

Magnets with varying magnetization direction and method of making such magnets patent, September 2005

Extrusion Press Die Assembly
patent-application, April 2014

Multi-Material Component and Methods of Making Thereof
patent-application, February 2018

Structure for joining members including a nut and an auxiliary member
patent, August 2012

Systems and Methods for Joining Components
patent-application, June 2016

Aluminum Alloy Extrudate Excellent In Bending Crush Resistance And Corrosion Resistance
patent-application, July 2012

Hybrid disk-cone extrusion die assembly
patent, October 2003

Friction Stir Extrusion of Nonweldable Materials for Downhole Tools
patent-application, August 2017

Friction-Stir Extruders and Friction-Stir Extrusion Processes
patent-application, March 2015

Joining Method
patent-application, May 2017

High-Strength Aluminum Alloy Product And Method Of Producing The Same
patent-application, March 2010

Mg-based alloy
patent, November 2012

Friction Stir Welding System and Method
patent-application, February 2008

Magnesium: Current and potential automotive applications
journal, February 2002

Enhanced Friction-Stir-Welding Joint Strength Between Steel and Aluminum with Surface Coating and Preformed Local Texture
patent-application, January 2017

Method for producing seamless hollow extruded products of aluminum alloy and die set therefor
patent-application, March 2012

System and Process for Friction Consolidation Fabrication of Permanent Magnets and Other Extrusion and Non-Extrusion Structures
patent-application, November 2014

Method for manufacturing permanent magnets
patent, January 1989

Tool Temperature and Process Modeling of Friction Stir Welding
journal, January 2018

Method of making bonded or sintered permanent magnets
patent, November 1995

A preliminary study on the feasibility of friction stir back extrusion
journal, May 2012

Method and apparatus for extrusion of tubing sheeting and profile shapes
patent, October 1995

Extrusion Press Systems And Methods
patent-application, April 2014

Friction Stir Weld Tool and Method
patent-application, December 2016

Friction Stir Welding Tool And Friction Stir Welding Method
patent-application, March 2009

Joined body and process for manufacturing the same
patent-application, November 2009

Metal Joining Method and Metal Joined Member
patent-application, June 2017

Method of making magnets by polymer-coating magnetic powder
patent, January 1976

Aluminium-steel lap joining by multipass friction stir welding
journal, September 2016

Method of making magnets
patent, July 1975

Friction stir welding tool having a counterflow pin configuration
patent-application, October 2008

Friction stirring interlocking of dissimilar materials
patent, August 2019

Different-Material Joining Structure
patent-application, December 2018

Method of making magnets
patent, August 1976

Friction-Stir Joining Method
patent-application, March 2014

Friction Stir Welding Method and Joined Body
patent-application, August 2017

Apparatus for Extruding Cylindrical Magnets
patent, February 1972

High ductility aluminum alloy made from powder by friction extrusion
journal, June 2019

Compositions and methods for dissimilar material welding
patent, April 2014

Extrusion Die for Forming Hollow Material
patent-application, August 2016

Induction Motor Rotor and a Method of Manufacturing the Same
patent-application, June 2017

Fabrication of High Performance Magnesium/Carbon-Fiber/PEEK Laminated Composites
journal, January 2003

Apparatus for ultrasonically assisted melt extrusion of fibers
patent, March 2000

Welded component
patent, January 2008

Forming metallic composite materials by urging base materials together under shear
patent, November 1993

Intermetallic compounds in Al 6016/IF-steel friction stir spot welds
journal, June 2010

Method of plastic forming of materials
patent, April 1998

Friction Spot Welding and Friction Seam Welding
patent-application, December 2015

Friction Stir Welding Tool and Process For Welding Dissimilar Materials
patent-application, December 2011

Microstructure and mechanical properties of equimolar FeCoCrNi high entropy alloy prepared via powder extrusion
journal, August 2016

Aluminium powder metallurgy technology for high-strength applications
journal, June 1981

Anisotropic nanocomposite rare earth permanent magnets and method of making
patent-application, January 2006

Aluminum alloy products and methods of preparation
patent, November 1976

Method of friction stir welding dissimilar metals and workpiece assemblies formed thereby
patent-application, May 2011

Method for Low-Temperature Joining of Metal Materials, and Joint Structure
patent-application, July 2021

Equal-Channel Angular Extrusion of a Low-Density High-Entropy Alloy Produced by High-Energy Cryogenic Mechanical Alloying
journal, September 2014

Densification of Thermal Spray Coatings
patent-application, December 2004

Method for Forming Hollow Profile Non-circular Extrusions Using Shear Assisted Processing and Extrusion (Shape)
patent-application, November 2018

Method for Operating Double-Action Friction Stir Welding Device, and Double-Action Friction Stir Welding Device
patent-application, March 2021

Joining of polymers and polymer-metal hybrid structures: Recent developments and trends
journal, August 2009

Extrusion of a Metal Alloy Containing Copper and Zinc
patent-application, August 2008

Controlled Speed Friction Stir Tool Probe Bodies Having Non-Linear, Continuous, Monotonically-Decreasing Curved Axial Profiles and Integrated Surface Features
patent-application, January 2016

Tool, apparatus, and method for welding workpieces
patent, January 2008

Shear-extrusion method
patent, August 2006

Method of Making Permanent Magnets
patent, May 1972

Composite Preform having a Controlled Fraction of Porosity in at Least one Layer and Methods for Manufacture and Use
patent-application, October 2009

Method of Joining Metallic Materials
patent-application, March 2004

Method and apparatus for extruding powdered material
patent, August 1995

In-Situ Interlocking of Metals Using Additive Friction Stir Processing
patent-application, June 2016

Joining of dissimilar materials
journal, January 2015

Solid State Joining Using Additive Friction Stir Processing
patent-application, June 2016

Friction stir welding tool having a scroll-free concentric region
patent, September 2011

Tapered extrusion die and method of forming the same
patent, September 1981

Corrosion resistant fluid conducting parts, methods of making corrosion resistant fluid conducting parts and equipment and parts replacement methods utilizing corrosion resistant fluid conducting parts
patent-application, February 2006

Method of Bonding Dissimilar Metal Materials and Bonded Body of Dissimilar Metal Materials
patent-application, March 2012

Method and apparatus for forming elongated articles having reduced diameter cross-sections
patent, November 1981

Nanocomposite Permanent Magnets And Methods Of Making The Same
patent-application, January 2014

Magnets with varying magnetization direction and method of making such magnets
patent, September 2005

Numerical studies on effect of axial pressure in friction stir welding
journal, April 2007

High energy ball milling method for making rare earth-transition metal-boron permanent magnets
patent, October 1988

Top Nd-Fe-B magnets with greater than 56 MGOe energy density and 9.8 kOe coercivity
journal, September 2002