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Shear Assisted Processing and Extrusion (ShAPE™) of AZ91E Flake: A Study of Tooling Features and Processing Effects

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Abstract

Charges of melt-spun AZ91E flake were indirectly extruded into tubes using Shear Assisted Processing and Extrusion (ShAPE™). The effect of instrument parameters and tool features on densification and microstructural evolution was studied. At a constant extrusion ratio, the tool rotational velocity varied from 75 to 300 rpm and was demonstrated to reduce the forge force by a factor of four. Modification of the extrusion die face with successively more aggressive scrolled features was found to enhance material flow into the extrusion orifice which led to a 30% reduction in spindle torque. Microstructure, texture and hardness are reported for the range of rpm and scroll geometries investigated. It was observed that the ShAPE™ process is able to retain the average grain size of the as-spun flake (2.5-4 μm) while simultaneously imparting strong textural alignment in the resultant tube.

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Acknowledgments

The authors would like to recognize US Magnesium LLC for supplying the material used in this study. Financial support for this work was awarded through the MS3 (Materials Synthesis and Simulation across Scales) Initiative at Pacific Northwest National Laboratory, a multi-program national laboratory operated by Battelle for the US Department of Energy under contract DE-AC05-76RL01830. A portion of this research was performed using EMSL, a DOE Office of Science User Facility sponsored by the Office of Biological and Environmental Research. Finally, we would like to thank Karl Mattlin for his assistance with AZ91 flake production and Clyde Chamberlin and Anthony Guzman for their help with sample polishing and preparations for metallurgical analysis.

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Authors and Affiliations

  1. Pacific Northwest National Laboratory, P.O. Box 999, Richland, WA, 99352, USA

    Jens T. Darsell, Nicole R. Overman, Vineet V. Joshi, Scott A. Whalen & Suveen N. Mathaudhu

  2. Department of Mechanical Engineering, University of California, Riverside, Riverside, CA, USA

    Suveen N. Mathaudhu

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  1. Jens T. Darsell
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  2. Nicole R. Overman
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Correspondence to Jens T. Darsell.

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Darsell, J.T., Overman, N.R., Joshi, V.V. et al. Shear Assisted Processing and Extrusion (ShAPE™) of AZ91E Flake: A Study of Tooling Features and Processing Effects. J. of Materi Eng and Perform 27, 4150–4161 (2018). https://doi.org/10.1007/s11665-018-3509-1

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  • DOI: https://doi.org/10.1007/s11665-018-3509-1

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