A method for manufacturing an aluminium tube, including providing a slug of an aluminium alloy consisting of >98.4% by weight of Al, 0.10% by weight to 0.30% by weight of Si, 0.25% by weight to 0.45% by weight of Fe, 0.01% by weight to 0.08% by weight of Cu, 0.15% by weight to 0.40% by weight of Mn, at most 0.15% by weight of Mg, at most 0.05% by weight of Zn, at most 0.05% by weight of Cr, at most 0.05% by weight of Ni, at most 0.05% by weight of Ti and at most 0.05% by weight of other impurities, wherein the aforementioned ingredients of the aluminium alloy add to 100% by weight, and impact extrusion of the slug to form an aluminium tube having a shoulder and a neck.

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.

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 method of forming a casting with a flow passage may include filling a tubular pipe with a filler to form a smart core; inserting the smart core into a mold having a cavity corresponding to a shape of the casting to be formed; injecting a molten metal into the cavity through a casting process; and removing the filler from the smart core, wherein a hardness of the tubular pipe is 70 Hv or more.

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.

In extrusion processing in which diameter reduction is performed by pressing a raw pipe having a core bar inserted therein into a die having a small inner diameter portion on its tip end side, a differential thickness pipe having a thick-walled portion at its tip end can be molded using a core bar having a small cross-section portion formed at its tip end. It is also possible to mold a differential thickness pipe having a thick-walled part at an intermediate axial position by using a raw pipe having a thin-walled portion at its tip end. For example, such a raw pipe can be molded by extrusion processing using a core bar having no small cross section portion at its tip end, prior to the above-described formation of the thick-walled portion. When higher dimensional accuracy is required, a so-called “counter punch” may be used in the formation of the thick-walled portion.

In a heat exchanger, an insertion hole of a header and an end portion of a heat exchange member can be properly joined. In the heat exchanger, the heat exchange member includes at least one heat transfer tube extending in the first direction and a fin that is formed at part of an end edge of the heat transfer tube in a second direction perpendicular to the first direction. The fin is provided at part of a portion of the heat exchange member that is other than an end portion thereof in the first direction. Part of the heat transfer tube that is located at the end portion of the heat exchange member has a smaller width in the second direction than a width of part of the heat transfer tube in the second direction that is located at a fin setting portion.

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.

The present disclosure describes a method of manufacturing a vehicle body structure component. The method includes extruding a tube to include at least one reinforced region extending along a length of the tube. The tube has a first thickness in the at least one reinforced region and a second thickness in other regions of the tube. The first thickness is greater than the second thickness. The method further includes cutting a blank from the tube such that the blank includes at least a portion of the at least one reinforced region and forming the blank into a desired shape of the component.

Metal sheets (13) are produced from strand-shaped profiles (8) having a low thickness, made of magnesium or magnesium alloys by way of an extrusion system (1). The open or closed extruded profile (8) exiting the extrusion die (6-7) of an extrusion press (1) is shaped to obtain a flat metal sheet (13) and is then subjected to a defined shaping process by way of stretch-forming. The system for carrying out the method is essentially composed of an extrusion press (1) comprising a die plate generating the extruded profile and a shaping unit (5) following the die plate, wherein the shaping unit (5) is composed of a severing unit (2), a bending unit (3), and an unrolling unit (4).