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.

Provided are an unequal-channel angular self-bending extrusion die and a method for designing and manufacturing the same and extrusion method thereof and includes following steps: designing a symmetrical streamlined extrusion die based on sine function; making the medial axis of the die cavity of the symmetrical streamlined extrusion die twisted and deformed on a certain plane; establishing the die cavity wall surface equation of the unequal-channel angular self-bending extrusion die; setting a working belt structure downstream the die cavity of the unequal-channel angular self-bending extrusion die.

Provided are an unequal-channel angular self-bending extrusion die and a method for designing and manufacturing the same and extrusion method thereof and includes following steps: designing a symmetrical streamlined extrusion die based on sine function; making the medial axis of the die cavity of the symmetrical streamlined extrusion die twisted and deformed on a certain plane; establishing the die cavity wall surface equation of the unequal-channel angular self-bending extrusion die; setting a working belt structure downstream the die cavity of the unequal-channel angular self-bending extrusion die.

An adjustable diameter die assembly for extruding a heated and malleable workpiece being forcefully moved downstream includes a die having a first ring and a second ring spaced apart from the first ring, the die having an axial portion extending intermediate the first and second rings that defines a throughbore having an axial diameter that is adjustable. The adjustable diameter die assembly includes a piston/cylinder combination operatively coupled to the die that, when actuated, causes (1) a compression of the first and second rings toward one another such that the axial diameter is decreased or (2) a stretching of the first and second rings away from one another such that the adjustable axial diameter is adjusted, respectively.

An adjustable diameter die assembly for extruding a heated and malleable workpiece being forcefully moved downstream includes a die having a first ring and a second ring spaced apart from the first ring, the die having an axial portion extending intermediate the first and second rings that defines a throughbore having an axial diameter that is adjustable. The adjustable diameter die assembly includes a piston/cylinder combination operatively coupled to the die that, when actuated, causes (1) a compression of the first and second rings toward one another such that the axial diameter is decreased or (2) a stretching of the first and second rings away from one another such that the adjustable axial diameter is adjusted, respectively.

A shear assisted extrusion process for producing cladded materials wherein a cladding material and a material to be cladded are placed in sequence with the cladded material positioned to contact a rotating scroll face first and the material to be cladded second. The two materials are fed through a shear assisted extrusion device at a preselected feed rate and impacted by a rotating scroll face to generate a cladded extrusion product. This process allows for increased through wall strength and decreases the brittleness in formed structures as compared to the prior art.

A shear assisted extrusion process for producing cladded materials wherein a cladding material and a material to be cladded are placed in sequence with the cladded material positioned to contact a rotating scroll face first and the material to be cladded second. The two materials are fed through a shear assisted extrusion device at a preselected feed rate and impacted by a rotating scroll face to generate a cladded extrusion product. This process allows for increased through wall strength and decreases the brittleness in formed structures as compared to the prior art.

A friction stir processing system can include a rotatable die assembly. The rotatable die assembly can include a die body and a plurality of die segments. The die body includes a die base and a die stem. The die stem extends axially from the die base, the die stem defines an extrusion cavity, and the die body is formed from a first material. The plurality of die stems are coupled to the die stem. The plurality of die segments are disposed around the extrusion cavity to collectively form a die surface opposite to the die base. The plurality of die segments are formed from a different material than the die body.

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.

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.