Shear-assisted extrusion assemblies are provided. The assemblies can include a billet containing assembly containing a billet comprising a billet outer material and a billet inner material in at least one cross-section; a tool operably engaged with the billet; an extrudate receiving channel configured to receive extrudate from the tool, wherein the extrudate comprises extruded outer material and extruded inner material in at least one cross-section, the extruded outer material being the same material as the billet outer material, and the extruded inner material being the same as the billet inner material. Methods for producing multi-material shear-assisted extrudate are also provided.

Shear-assisted extrusion assemblies are provided. The assemblies can include a billet containing assembly containing a billet comprising a billet outer material and a billet inner material in at least one cross-section; a tool operably engaged with the billet; an extrudate receiving channel configured to receive extrudate from the tool, wherein the extrudate comprises extruded outer material and extruded inner material in at least one cross-section, the extruded outer material being the same material as the billet outer material, and the extruded inner material being the same as the billet inner material. Methods for producing multi-material shear-assisted extrudate are also provided.

A system and method for an improved material flow through an extrusion machine by altering the material properties in a magnetic field are provided. The electromagnetic extrusion system includes a ram that is moved into a chamber containing an extrusion material to force the extrusion material out of an opening defined, at least in part, by a die to create an extrusion with a cross-sectional shape corresponding to the predetermined shape of the opening. An electromagnetic winding of electrically conductive material is embedded within a tool retainer block surrounding the container and is helically wound about the chamber and carries a DC electrical current to generate a magnetic field having a magnetic flux density of at least 2 Tesla within the extrusion material to dissipate dislocation defect structures in the extrusion material being extruded via the magnetoplasticity effect. The magnetic field therefore provides for reduced flow stress on the tooling.

A system and method for an improved material flow through an extrusion machine by altering the material properties in a magnetic field are provided. The electromagnetic extrusion system includes a ram that is moved into a chamber containing an extrusion material to force the extrusion material out of an opening defined, at least in part, by a die to create an extrusion with a cross-sectional shape corresponding to the predetermined shape of the opening. An electromagnetic winding of electrically conductive material is embedded within a tool retainer block surrounding the container and is helically wound about the chamber and carries a DC electrical current to generate a magnetic field having a magnetic flux density of at least 2 Tesla within the extrusion material to dissipate dislocation defect structures in the extrusion material being extruded via the magnetoplasticity effect. The magnetic field therefore provides for reduced flow stress on the tooling.

A metal matrix composite material and associated methods are disclosed. In one example, the metal matrix composite material includes ceramic particles distributed in multiple phases. In selected examples, the metal matrix composite material is formed by a process including applying a rotational force and an axial force to a feedstock at an interface and plasticizing a portion of the feedstock at the interface.

A metal matrix composite material and associated methods are disclosed. In one example, the metal matrix composite material includes ceramic particles distributed in multiple phases. In selected examples, the metal matrix composite material is formed by a process including applying a rotational force and an axial force to a feedstock at an interface and plasticizing a portion of the feedstock at the interface.

A method for shear-assisted extrusion of a billet or feedstock can involve extruding a first portion of the feedstock through a die opening while rotating the die face relative to the feedstock at a first rotational rate and applying a first axial extrusion force. A second portion of the feedstock can be extruded through the opening while rotating the die face at a second rotational rate and applying a second axial extrusion force. This can establish different temperature ranges at the interface for each portion, resulting in a first extruded portion with different physical properties than the second extruded portion.

A method for shear-assisted extrusion of a billet or feedstock can involve extruding a first portion of the feedstock through a die opening while rotating the die face relative to the feedstock at a first rotational rate and applying a first axial extrusion force. A second portion of the feedstock can be extruded through the opening while rotating the die face at a second rotational rate and applying a second axial extrusion force. This can establish different temperature ranges at the interface for each portion, resulting in a first extruded portion with different physical properties than the second extruded portion.

A method for making a profile with a micro-hole, in particular using a continuous composite extrusion process, comprises embedding, in a position in a matrix of the profile to be formed where a micro-hole is to be formed, a continuous wire having a shape and size consistent with that of the micro-hole; sawing a composite profile with the wire obtained by extrusion to a desired length; and removing the wire from the sawed composite profile using a predetermined physical or chemical method without changing the matrix of the composite profile so that the micro-hole of the predetermined size and shape is formed in the predetermined position in the profile. This method is simple, does not require any large, expensive, and sophisticated equipment, can produce continuous micro-holes of different specifications, and can be used in a wide variety of applications.

A method for making a profile with a micro-hole, in particular using a continuous composite extrusion process, comprises embedding, in a position in a matrix of the profile to be formed where a micro-hole is to be formed, a continuous wire having a shape and size consistent with that of the micro-hole; sawing a composite profile with the wire obtained by extrusion to a desired length; and removing the wire from the sawed composite profile using a predetermined physical or chemical method without changing the matrix of the composite profile so that the micro-hole of the predetermined size and shape is formed in the predetermined position in the profile. This method is simple, does not require any large, expensive, and sophisticated equipment, can produce continuous micro-holes of different specifications, and can be used in a wide variety of applications.