Systems and methods for quenching an extrudate using an atomized spray of liquid are described. A system includes a billet die at a proximal end configured to accept a billet and form an extrudate, a quench chamber located adjacent to the billet die for receiving the extrudate and comprising at least one pulsed width modulation (PWM) atomizing spray nozzle and a control module in communication with the at least one PWM atomizing spray nozzle and configured to independently control a liquid pressure, a gas pressure, a spray frequency, a duty cycle and flow rate of each at least one PWM atomizing spray nozzle.

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.

Fe-6.5% Si electrical steel is alloyed with boron to reduce its melting temperature and interfacial energy to improve processability for melt-spinning applications. Boron additions from 0.01 wt % to 2.24 wt % into Fe-6.5% Si and its effect on ribbon thickness, grain size, magnetic, and mechanical properties are disclosed. Minor boron alloying significantly changed the melt pool stability and wetting on a melt-spinning quench wheel and in turn increased the quench rate with minimum impact on the magnetic saturation and ductility. Boron addition of less than 0.06 wt % was also found beneficial to the magnetic property of the alloy by lowering both its hysteresis and eddy current losses.

Shear assisted extrusion apparatus, tools, inserts, and/or methods are provided. The apparatuses can include: an extrusion receiving channel operably engaged with a tool to receive extruded material; and one or more openings aligned between the spindle ends, the openings configured to convey fluid to the extruded product. Example tools can include one or more openings aligned between the tool ends. Example methods can include quenching plasticized feed material before exiting the spindle. A spindle assembly and/or tool assembly inserts are also provided that can include a sleeve extending within one or both of the spindle assembly or tool assembly of the apparatus; and openings within the sleeve configured to convey fluid to within one or both of the receiving channel of the spindle assembly or the tool assembly.

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.

Disclosed is an extruded aluminum wire including: Fe, Cu, Ti, Mn, Mg, Cr, B, Ga, V and Zn in the total content of 0.01% by mass or less, and one or more components selected from the group consisting of Ni, Y and Si, with the balance being Al and inevitable impurities, wherein, in a cross-section perpendicular to the longitudinal direction of the extruded wire, an average grain size measured by electron backscatter diffraction is 15 to 50 m, respectively, in both a central measurement region including a center point of the cross-section and a peripheral measurement region in contact with the outer periphery of the cross-section.

Systems and methods for quenching an extrudate using an atomized spray of liquid are described. A system includes a billet die at a proximal end configured to accept a billet and form an extrudate, a quench chamber located adjacent to the billet die for receiving the extrudate and comprising at least one pulsed width modulation (PWM) atomizing spray nozzle and a control module in communication with the at least one PWM atomizing spray nozzle and configured to independently control a liquid pressure, a gas pressure, a spray frequency, a duty cycle and flow rate of each at least one PWM atomizing spray nozzle.