A special-purpose die for shaping an aluminum-magnesium alloy by rotating extrusion is provided, including a male die and a female die, wherein a trapezoidally-sectioned groove is formed at an end portion of a working area of the male die, an inner portion of the male die is hollow, with the hollow inner portion having sections of equal area, a circumferential wall of a die cavity of the female die is provided with at least two symmetrical axial grooves, and a cavity is formed inside a clamping part of the female die. The present disclosure remarkably reduces the axial extrusion force such that the deformation of the formed workpiece is more uniform, which greatly improves the mechanical property of the formed workpiece.

Provided is a method of forming a cup-shaped aluminum-magnesium-alloy article by rotary extrusion, including the following steps. (1) Blanking. (2) Performing rotary extrusion: placing a cylindrical billet into a concave die cavity, wherein a peripheral wall of the cavity of the concave die is provided with at least two symmetrical axial grooves; inserting a convex die into the concave die cavity, wherein an end of a working region of the convex die is provided with a groove of a trapezoidal cross section; subjecting the convex die to forward extrusion and heating, and simultaneously rotating and heating the concave die, wherein an integral torque is formed during the extrusion process of the convex die by using the cylindrical billet inside the groove having a trapezoidal cross section, and wherein a synchronized rotation with the concave die is achieved by using a metallic billet that flows into the axial groove. (3) Demolding.

Provided is a method of forming a cup-shaped aluminum-magnesium-alloy article by rotary extrusion, including the following steps. (1) Blanking. (2) Performing rotary extrusion: placing a cylindrical billet into a concave die cavity, wherein a peripheral wall of the cavity of the concave die is provided with at least two symmetrical axial grooves; inserting a convex die into the concave die cavity, wherein an end of a working region of the convex die is provided with a groove of a trapezoidal cross section; subjecting the convex die to forward extrusion and heating, and simultaneously rotating and heating the concave die, wherein an integral torque is formed during the extrusion process of the convex die by using the cylindrical billet inside the groove having a trapezoidal cross section, and wherein a synchronized rotation with the concave die is achieved by using a metallic billet that flows into the axial groove. (3) Demolding.

A method of pre-heating an extrusion die comprises heating an extrusion die using a first group of heating elements and a second group of heating elements; and then heating the extrusion die using only the first group of heating elements to bring the extrusion die to a desired pre-heat temperature, or heating the extrusion die using the first and second groups of heating elements, the second group of heating elements being operated at reduced power, to bring the extrusion die to a desired pre-heat temperature.

A method of pre-heating an extrusion die comprises heating an extrusion die using a first group of heating elements and a second group of heating elements; and then heating the extrusion die using only the first group of heating elements to bring the extrusion die to a desired pre-heat temperature, or heating the extrusion die using the first and second groups of heating elements, the second group of heating elements being operated at reduced power, to bring the extrusion die to a desired pre-heat temperature.

An additive manufacturing (AM) extrusion die system having an extrusion die configured to receive a material to be extruded. The extrusion die includes a main body having a cylindrical section and a distal tapered section terminating at an extruder tip. The main body is configured to mount to a barrel of an additive manufacturing system. The die further includes a central extruder channel extending axially along the main body configured to receive the material at the cylindrical section of the main body and output the material at the extruder tip of the main body, and a cartridge heater slot formed within the main body and generally parallel to the central extruder channel. The cartridge heater slot configured to receive a cartridge heater therein for imparting thermal energy to the material within the central extruder channel. A cooling system is provided for controlling a temperature of the material.

An additive manufacturing (AM) extrusion die system having an extrusion die configured to receive a material to be extruded. The extrusion die includes a main body having a cylindrical section and a distal tapered section terminating at an extruder tip. The main body is configured to mount to a barrel of an additive manufacturing system. The die further includes a central extruder channel extending axially along the main body configured to receive the material at the cylindrical section of the main body and output the material at the extruder tip of the main body, and a cartridge heater slot formed within the main body and generally parallel to the central extruder channel. The cartridge heater slot configured to receive a cartridge heater therein for imparting thermal energy to the material within the central extruder channel. A cooling system is provided for controlling a temperature of the material.

A raw material of aluminum base alloy is extruded and formed by using a forming pattern comprising an upper pattern having plural through-holes for supplying the raw material into diaphragms of equal angles on the circumference and circular cylindrical protrusions positioned in the center of plural through-holes so as to be surrounded by plural through-holes at the exit side of the through-holes, and a lower pattern positioned in the concave portions commonly penetrating at the exit of the plural through-holes of the upper pattern, having through-holes for inserting the protrusions of circular circumference of the upper pattern by providing a tube forming gap, positioned in the center of concave portions of the concave portions in the circular columnar shape of the upper pattern.

A raw material of aluminum base alloy is extruded and formed by using a forming pattern comprising an upper pattern having plural through-holes for supplying the raw material into diaphragms of equal angles on the circumference and circular cylindrical protrusions positioned in the center of plural through-holes so as to be surrounded by plural through-holes at the exit side of the through-holes, and a lower pattern positioned in the concave portions commonly penetrating at the exit of the plural through-holes of the upper pattern, having through-holes for inserting the protrusions of circular circumference of the upper pattern by providing a tube forming gap, positioned in the center of concave portions of the concave portions in the circular columnar shape of the upper pattern.

A method and apparatus for additive manufacturing that includes a material guide for directing a supply of working material. An electro-magnetic heater is provided to heat and deposit molten working material as a new supply of working material is forced through the material guide. A single or twin screw extruder is provided within for advancing, mixing and/or depositing the working material through a tip positioned at an end of the material guide.