A method for producing a replaceable cutting head is described. The replaceable cutting head is manufactured by extruding a blank. During extrusion of the blank, a number of helical coolant channels and a number of helical flutes are simultaneously formed. After extrusion, the flutes have a first angle of twist (D1), and the coolant channels have a second angle of twist (D2). After extrusion, the blank is sintered and then reworked to selectively adjust the first angle of twist (D1) and the pitch of the flutes. The method produces an endless blank that is capable of being parted off to a desired length without any sacrificial allowance, which provides significant material and cost savings as compared to conventional methods.

An extrusion feedstock material is provided, the material comprising a length of one material extending from a first end to a second end; and at least one slot extending lengthwise within the one material between the first and second ends of the material. A process for extruding conductive material is also provided, the process comprising providing both rotational and axial forces between a die tool and a length of feedstock material to form an extrusion product, wherein the length of feedstock and conductive material comprise Al and NanoCrystalline Carbon Forms (NCCF). A process for extruding material is provided, the process comprising: providing both rotational and axial forces between a die tool and a length of feedstock material to form an extrusion product, wherein the length of feedstock material comprises: a length of material extending from a first end to a second end; and at least one slot extending lengthwise within the material between the first and second ends of the material. A conductive extrudate material is provided comprising Al and NanoCrystalline Carbon Forms (NCCF).

A processing die and a preparation method for a fastener are provided. The processing die includes a punch and a die. The top of the punch and the bottom of the die are configured for being connected with a hydraulic press, the die includes a first half die and a second half die which are clamped to form an inlet channel, an expansion corner channel and a torsion channel, and an extrusion channel is included in the forming sliding block, the inlet channel, the expansion corner channel, the torsion channel and the extrusion channel are sequentially assembled to form a die channel cavity, and a billet to be processed is successively subjected to upsetting, shearing, torsion and extrusion in a single die under the pressure of the punch.

Certain exemplary embodiments can provide a manufacturing method, process, machine, and/or system for continuously consolidating granular materials, creating new alloys and/or composites, and/or modifying and/or refining material microstructure, by using plastic deformation of feedstock(s) provided in various structural forms. Materials produced during this process can be fabricated directly and/or in forms such as, e.g., wires, rods, tubes, sheets, plate and/or channels, etc.

A preparation method of a uniform low stress cone shaped charge liner includes the steps of multi-pass extrusion forming, vibration aging treatment, and cryogenic treatment. The step of multi-pass extrusion forming refers to 4 to 8 passes of extrusion deformation under the actions of a three-dimensional compressive stress and a deformation rate of 5 to 10 mm/s, having a deformation amount of 5 to 50% for each pass. The shaped charge liner prepared by the present invention has high dimensional accuracy, good geometric symmetry, low stress value, and excellent stability in the precise machining process and in use, which may significantly improve the penetration capability and stability of the shaped charge liner of high-explosive anti-tank warheads.

Shear-assisted extrusion processes for forming extrusions of a desired composition from a feedstock material are provided. The processes can include applying a rotational shearing force and an axial extrusion to the same location on the feedstock material. Devices for this can include a die tool defined by a die face extending from a rim of the die face inwardly at an angle greater than zero in relation to a sidewall of the die tool in at least one cross section; and/or a die tool defining an opening configured to receive feedstock material for extrusion and further defining a die face defining a recess within the die face and contiguous with the opening. Shear-assisted extrusion processes are also provided that can mix different portions of the feedstock material within a recess about the opening prior to feedstock material entering the opening; and extruding the mixed portions.

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.

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.