Battelle Memorial Institute

Curt A Lavender

Glenn J Grant

Vineet V Joshi

Scott A Whalen

Jens T Darsell

Aashish Rohatgi

Md Reza-E-Rabby

Saumyadeep Jana

John G Frye

Jin Yong Kim

Kenneth Scott Weil

David Catalini

Jun Cui

Darrell R Herling

Brandon Scott Taysom

Mageshwari Komarasamy

Sina Shahrezaei

Rob J Seffens

Mark A Rhodes

William E Frazier, Iii

Kevin Lynn Simmons

Norman Lynn Newhouse

Paul H Humble

Dustin D Caldwell

Brian Christopher Yeggy

Guosheng Li

Yuri Hovanski

Ward Evan TeGrotenhuis

Kenneth I Johnson

Jung Pyung Choi

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.

Method for forming hollow profile non-circular extrusions using shear assisted processing and extrusion (ShAPE)

A shear assisted extrusion process for producing cladded materials wherein a cladding material and a material to be cladded are placed in sequence with the cladded material positioned to contact a rotating scroll face first and the material to be cladded second. The two materials are fed through a shear assisted extrusion device at a preselected feed rate and impacted by a rotating scroll face to generate a cladded extrusion product. This process allows for increased through wall strength and decreases the brittleness in formed structures as compared to the prior art.

Functionally graded coatings and claddings

Devices and methods for performing shear-assisted extrusion processes for forming extrusions of a desired composition from a feedstock material are provided. The processes can use a device having a scroll face having an inner diameter portion bounded by an outer diameter portion, and a member extending from the inner diameter portion beyond a surface of the outer diameter portion. Extrusion feedstocks and extrusion processes are provided for forming extrusions of a desired composition from a feedstock. The processes can include providing a feedstock having at least two different materials and engaging the materials with one another within a feedstock container. Methods for preparing metal sheets are provided that can include preparing a metal tube via shear assisted processing and extrusion; opening the metal tube to form a sheet having a first thickness; and rolling the sheet to a second thickness that is less than the first thickness.

Devices and methods for performing shear-assisted extrusion, extrusion feedstocks, extrusion processes, and methods for preparing metal sheets

Riveted assemblies are provided that can include: a first component having opposing first and second sidewalls; a second component having opposing third and fourth sidewalls, wherein the second sidewall of the first component abuts the third sidewall of the second component to bind and form an affixing interface comprising the second and third sidewall between the first component to the second component; and a rivet extending between a head along a shank to an end, the rivet piercing the first sidewall with the end of the rivet being between the first and fourth sidewalls. Methods for affixing at least two components using a rivet are also provided. The methods can include: providing a first component having opposing first and second sidewalls; providing a second component having opposing third and fourth sidewalls; abutting the second sidewall of the first component to the third sidewall of the second component; providing a rivet extending between a head along a shank to an end; projecting the rivet through at least the first sidewall of the first component to form an affixing interface comprising the second and third sidewalls.

Riveted assemblies and methods for riveting components

Extrusion processes for forming extrusions of a desired composition from a feedstock

Shear assisted extrusion process

Method for Forming Hollow Profile Non-Circular Extrusions Using Shear Assisted Processing and Extrusion (ShAPE)

Methods are provided for synthesizing high purity niobium or rhenium powders by a combustion reaction. The methods can include: forming a combustion synthesis solution by dissolving in water an oxidizer, a fuel, and at least one base-soluble, ammonium salt of niobium or rhenium in amounts that yield a stoichiometric burn when combusted; and heating the combustion synthesis solution to a temperature sufficient to substantially remove the water and to initiate a self-sustaining combustion reaction.

Methods for synthesizing high purity niobium or rhenium powders

A die tool and process are described that provide friction consolidation fabrication and friction consolidation extrusion fabrication products including permanent magnets, and other extrusion and non-extrusion structures. The present invention overcomes previous particle size, texture, homogeneity and density limitations in conventional metallurgy processes.

System and process for friction consolidation fabrication of permanent magnets and other extrusion and non-extrusion structures

Nanocrystalline metal powders comprising tungsten, molybdenum, rhenium and/or niobium can be synthesized using a combustion reaction. Methods for synthesizing the nanocrystalline metal powders are characterized by forming a combustion synthesis solution by dissolving in water an oxidizer, a fuel, and a base-soluble, ammonium precursor of tungsten, molybdenum, rhenium, or niobium in amounts that yield a stoichiometric burn when combusted. The combustion synthesis solution is then heated to a temperature sufficient to substantially remove water and to initiate a self-sustaining combustion reaction. The resulting powder can be subsequently reduced to metal form by heating in a reducing gas environment.

Production of nanocrystalline metal powders via combustion reaction synthesis

A scalable process is detailed for forming bulk quantities of high-purity &#x3b1;-MnBi phase materials suitable for fabrication of MnBi based permanent magnets.

Process for preparing scalable quantities of high purity manganese bismuth magnetic materials for fabrication of permanent magnets

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Richland, WA, United States of America

Curt A Lavender