An improved system and method of producing nanostructured or ultrafine grained metals is disclosed. In one embodiment, an improved system and method of producing nanostructured materials includes extruding the material through two deformation zones. The first zone consists of an inlet channel for inputting the material and a narrow channel through which the material is extruded, thus reducing its diameter. The second zone is an angular channel through which the compressed reduced diameter material is extruded to increase its diameter back to the original diameter. This eliminates the need for a dual press to provide back pressure to the material for increasing its diameter. Moreover, the total amount of strain applied to the material includes strain applied as a result of extrusion through the narrow channel and strain applied as a result of extrusion through the angular channel. As a result of the additional strain, fewer passes through the system are needed to achieve a desire strength.

A system and method provide a material with uniform micro-structure. In an embodiment, an equal channel angular extrusion system includes an interior mandrel. The interior mandrel includes an expanding shear material section and a contracting shear material section. In addition, the system includes a material. The material is disposed about a portion of the interior mandrel. Moreover, the system includes a pressure application device. The pressure application device applies pressure to the material to force the material to contact the expanding shear material section to provide an expanded post-shear material section. Pressure from the pressure application device applies pressure to the material to force the expanded post-shear material section to contact the contracting shear material section to provide a contracted shear material section.

A method of producing ultrafine-grained materials and a system for mass production of ultrafine-grained materials is disclosed. The system includes a die assembly with a die channel that extends from a first end to a second end. The system also includes first punch and a second punch. A lubricant is poured into a portion of the die channel to surround a workpiece that is positioned within the die channel in order to minimize the effects of friction during processing.

An equal channel angular extrusion tool comprising a punch assembly, a die set assembly, a base assembly, and a bottom slider assembly. The punch assembly comprises a punch, a punch nose, and a punch trolley. The die set assembly comprises an inlet channel and a removable core. The base assembly comprises a lifting mechanism which further comprises a die lift cylinder and a hold down ram. The bottom slider assembly comprises an ejection ram. The tool also includes a billet. The billet may be disposed in the bottom slider assembly. Severe plastic deformation is applied to the billet in the bottom slider assembly.

The ultra-fine wire fabricating apparatus comprises a feeder assembly, a stationary die, and a rotary die holder. The feeder assembly supplies a wire. The stationary die comprises a hollow inclined channel configured on an inner surface of the stationary die. The hollow inclined channel is configured to receive the wire from the feeder assembly. The rotary die holder configured to receive the wire from the stationary die and simultaneously torsionally deform the wire, wherein the rotary die holder rotates relative to the stationary die to produce the ultra-fine wire with improved mechanical properties. The method ensures continuous grain refinement of wires. The wires are severe plastic deformed using the combined effects of the stationary die and rotary die holder. The mechanical properties of the raw materials are improved due to a grain refinement and microstructure evolution caused by plastic deformation.

The present disclosure provides a method of forming an extruded billet from a coarse-grained magnesium alloy billet. The method includes extruding the coarse-grained magnesium alloy biller at temperatures greater than or equal to about 300 C. to less than or equal to about 360 C. to from the extruded billet. The coarse-grained magnesium alloy billet has an average grain size greater than or equal to about 800 m, and has a low aluminum content. The coarse-grained magnesium alloy billet includes greater than or equal to about 0.5 wt. % to less than or equal to about 3 wt. % of aluminum. The extruded billet may have a plurality of twins with lenticular morphology, which occupies an area fraction greater than or equal to about 20% of a total area of the extruded billet.

Systems, devices, and methods are described for extruding materials. In certain embodiments, one or more hollow billets are loaded onto an elongate mandrel bar and transported along the mandrel bar to a rotating die. The billets are transported through fluid clamps, which engage the mandrel bar and provide cooling fluid to the mandrel bar tip, and through mandrel grips, which engage the mandrel bar and prevent the mandrel bar from rotating. One or more press-rams advance the billets through a centering insert and into the rotating die. A quench assembly is provided at an extrusion end of the extrusion press to quench the extruded material. A programmable logic controller may be provided to control, at least in part, operations of the extrusion press system.

A high strength aluminum alloy material comprises aluminum as a primary component and at least one of magnesium and silicon as a secondary component at a concentration of at least 0.2% by weight. The material has a Brinell hardness of at least 90 BHN, a yield strength of at least 250 MPa, an ultimate tensile strength of at least 275 MPa, and a percent elongation of at least 11.5%.

Systems, devices, and methods are described for extruding materials. In certain embodiments, one or more hollow billets are loaded onto an elongate mandrel bar and transported along the mandrel bar to a rotating die. The billets are transported through fluid clamps, which engage the mandrel bar and provide cooling fluid to the mandrel bar tip, and through mandrel grips, which engage the mandrel bar and prevent the mandrel bar from rotating. One or more press-rams advance the billets through a centering insert and into the rotating die. A quench assembly is provided at an extrusion end of the extrusion press to quench the extruded material. A programmable logic controller may be provided to control, at least in part, operations of the extrusion press system.

A method for preparing a shear-assisted extruded material from a powder billet is provided, the method comprising providing a billet of material in substantially powder form; applying both axial and rotational pressure to the material to deform at least some of the contacted material; and extruding the material to form an extruded material. A method for preparing shear-assisted extruded material is provided, the method comprising applying both axial and rotational pressure to stock material to form an extruded material at a rate between 2 and 13 m/min. A method for preparing shear-assisted extruded material is provided. The method comprises applying both axial and rotational pressure to stock material to form an extruded material; and aging the extruded material for less than 3 hours. A method for preparing shear-assisted extruded material is provided. The method comprises providing a stock material for shear-assisted extrusion; and applying both axial and rotational force to the stock material to form an extruded material, wherein the axial force does not decrease during the extrusion.