Researchers have developed a new process that cuts in half the energy needed to manufacture high-performance aluminum alloys.
Researchers at the Pacific Northwest National Laboratory have developed a new process that cuts in half the energy needed to manufacture high-performance
According to the scientists, Shear Assisted Processing and Extrusion technology can eliminate heat treatment steps in the production process, resulting in significant energy savings and reduced emissions.ShAPE has been defined as a green, affordable manufacturing approach that enables the broad use of high-performance aluminum alloys in automotive applications.
In the ShAPE machine, the metal billet is simultaneously pushed through a small opening in a die which rotates. Together, the rotational movement and deformation thoroughly mix the metal elements as they are being extruded. In other words, the new process homogenizes the metal billet in a few seconds, immediately before it is extruded. This eliminates the need for a day-long, pre-heating homogenization step and means that no additional energy is used to heat the billet during extrusion. Together, this results in energy savings of up to 50%.
Whalen and his colleague Tianhao Wang ran some performance testing that showed that their technology also improves how well the individual alloying elements are mixed, leading to a better final product. In detail, components made of aluminum alloys processed with ShAPE exceeded current American Society for Testing and Materials standards for strength and elongation.
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