Friction Extrusion: Solid-State Metal Synthesis and Recycling in Sustainable Manufacturing

Zhili Feng; S. A. David; V. K. Manchiraju; D. A. Frederick; W. Thomas

doi:10.1007/s11837-023-05824-4

Friction Extrusion: Solid-State Metal Synthesis and Recycling in Sustainable Manufacturing

Zhili Feng, S. A. David, V. K. Manchiraju, D. A. Frederick, W. Thomas

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4 Scopus citations

Abstract

Friction extrusion (FE) is a novel solid-state process for synthesis and recycling of metals and alloys. The novelty of FE is that it utilizes the frictional heating and extensive plastic deformation intrinsic in the process to stir, mechanically alloy, consolidate, and convert powders, chips, and other recyclable feedstock metals into a usable product form of highly engineered materials. FE represents a potentially transformational sustainable manufacturing technology. Being a solid-state process, it eliminates the energy-intensive melting and solidification steps, which are necessary in the conventional metal recycle and synthesis processes. Therefore, FE is a highly energy-efficient, practically zero-emission, and economically competitive process. In this work, the concept and configuration of FE are introduced, the energy-saving advantage of FE is analyzed, the feasibility of FE is demonstrated with synthesizing Al alloys, and the results of some metallographic and mechanical properties studies are presented. A prognosis of the friction extrusion technology is outlined.

Original language	English
Pages (from-to)	2962-2973
Number of pages	12
Journal	JOM
Volume	75
Issue number	8
DOIs	https://doi.org/10.1007/s11837-023-05824-4
State	Published - Aug 2023

Funding

This manuscript has been authored by UT-Battelle, LLC, under Contract No. DE-AC05- 00OR22725 with the US Department of Energy. The United States Government retains and the publisher, by accepting the article for publication, acknowledges that the United States Government retains a non- exclusive, paid-up, irrevocable, world-wide license to publish or reproduce the published form of this manuscript, or allow others to do so, for United States Government purposes. The Department of Energy will provide public access to these results of federally sponsored research in accordance with the DOE Public Access Plan ( http://energy.gov/downloads/doe-public-access-plan ). This research was sponsored by the US Department of Energy under Award No. DE EE003458. The authors thank Dr. Jian Chen for his help with the figures.

Funders	Funder number
U.S. Department of Energy	DE EE003458

UN SDGs

This output contributes to the following UN Sustainable Development Goals (SDGs)

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abstract = "Friction extrusion (FE) is a novel solid-state process for synthesis and recycling of metals and alloys. The novelty of FE is that it utilizes the frictional heating and extensive plastic deformation intrinsic in the process to stir, mechanically alloy, consolidate, and convert powders, chips, and other recyclable feedstock metals into a usable product form of highly engineered materials. FE represents a potentially transformational sustainable manufacturing technology. Being a solid-state process, it eliminates the energy-intensive melting and solidification steps, which are necessary in the conventional metal recycle and synthesis processes. Therefore, FE is a highly energy-efficient, practically zero-emission, and economically competitive process. In this work, the concept and configuration of FE are introduced, the energy-saving advantage of FE is analyzed, the feasibility of FE is demonstrated with synthesizing Al alloys, and the results of some metallographic and mechanical properties studies are presented. A prognosis of the friction extrusion technology is outlined.",

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AU - Thomas, W.

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AB - Friction extrusion (FE) is a novel solid-state process for synthesis and recycling of metals and alloys. The novelty of FE is that it utilizes the frictional heating and extensive plastic deformation intrinsic in the process to stir, mechanically alloy, consolidate, and convert powders, chips, and other recyclable feedstock metals into a usable product form of highly engineered materials. FE represents a potentially transformational sustainable manufacturing technology. Being a solid-state process, it eliminates the energy-intensive melting and solidification steps, which are necessary in the conventional metal recycle and synthesis processes. Therefore, FE is a highly energy-efficient, practically zero-emission, and economically competitive process. In this work, the concept and configuration of FE are introduced, the energy-saving advantage of FE is analyzed, the feasibility of FE is demonstrated with synthesizing Al alloys, and the results of some metallographic and mechanical properties studies are presented. A prognosis of the friction extrusion technology is outlined.

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Friction Extrusion: Solid-State Metal Synthesis and Recycling in Sustainable Manufacturing

Abstract

Funding

UN SDGs

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