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 metallic material manufactured by a method including steps of (1) subjecting a semifinished metallic billet having at least one of a nanocrystalline microstructure and an ultrafine-grained microstructure to a rotary incremental forming process to form an intermediate wrought metallic billet and (2) subjecting the intermediate wrought metallic billet to a high rate forming process, wherein the high rate forming process includes a high rate forming process average equivalent strain rate, the high rate forming process average equivalent strain rate being at least about 0.1 s−1.

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 metal fused, deposition printer, that uses the thixotropic (or other) properties of a metal (or alloy) to control the viscosity of the material being deposited. In the invention presented in this patent, the viscosity of the metal is controlled by shearing it before, during, or after the deposition process. Since thixotropic (or other) properties allow for the control of the viscosity separately from the temperature, the taught invention allows for precise control of the temperature differential between the layer being deposited, and the substrate layer.

A shell (10) acts as a transporting shoe for steel ingots, which are pushed through a preferably tubular induction furnace for inductive heating for the purpose of producing seamless tubes by the extrusion process. The shell (10) is formed in such a way that it partially reaches around the contour of the steel ingot to be heated. The shell is provided at one end leading in the pushing-through direction or transporting direction, with a shoulder (12), which extends at an angle to the transporting direction, against which the steel ingot rests in such a way that the pushed-through steel ingot takes the shell (10) along with it. A method for inductively heating steel ingots uses a shell (10) as described.

A method for manufacturing a foam in a conduit comprises extruding a metal conduit. A metal foam powder is injected into a cavity of the metal conduit. The metal foam powder is activated to form a metal foam in the cavity of the metal conduit. A device for producing a foamed metal comprises an extruder that comprises one or more screws for extruding a metal through a die to form a conduit. The die comprises a plurality of ports for injecting a metal foam powder into a central hollow cavity or a wall cavity of the conduit. The device comprises a pressurizing section for increasing pressure on the metal foam powder and a thermal section for increasing the temperature of the metal foam powder to facilitate its expansion into a metal foam.

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 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.

An extrusion forming apparatus includes a mold disposed in a front open end of an extruding channel of a housing, a holding seat disposed in front of the front open end and partially extending into the extruding channel to abut the mold, and a vibrating source connected to the housing in abutment with the holding seat and controllable to apply an ultrasonic energy to the mold through the holding seat. An extrusion forming method is carried out by the extrusion forming apparatus. An extruded product is made by the extrusion forming method using the extrusion forming apparatus.