Friction extrusion (FE) was invented by researchers at The Welding Institute in 1991. Since then, it has largely been of interest for materials research since there has been no adequate equipment to explore its commercial uses. Those days are over now.

Bond Technologies has developed the world’s first, purpose-built friction extrusion (FE) system for the reprocessing of powders, chips or bulk materials into exciting new materials.

The first of its kind, the Bond model FE100 brings a new way to create metal shapes with the unique characteristics of friction-based metals processing. This machine has the extreme force and torque needed to extrude feedstock into wire, rod or tubes that are of a useful size.

“We remain ever-committed to advancing friction-based metals processing across all industries,” said Dave Hofferbert, President of Bond Technologies. “Being the first on the globe to bring to market a purpose-built Friction Extrusion machine is a testament to that dedication. There are currently two FE100 machines in use today, both being used to directly consolidate powders and reprocess bulk materials. We can’t help but be excited about this.”

DAVE HOFFERBERT, PRESIDENT OF BOND TECHNOLOGIES

For more than a decade, Bond Technologies has remained committed to pushing FSW and FE Technology forward

The FE100 machine, said Hofferbert, has many commercial applications – one of which is the potential to help the additive manufacturing industry make big advances in different ways. For example, there is the possibility of producing bar stock from engineered powder using the FE100, which can then be used as weld wire or stock for a friction deposition system, producing ultra-fine-grained structures, possibly with embedded particles.

“Over the last 10 or 15 years, we’ve seen more and more companies taking traditional welding processes and turning them into 3D printing processes,” explained Hofferbert. “The capabilities of our friction extrusion machine in reprocessing metal powder, machining waste or solid billet into new materials lends itself to applications in the automotive, aerospace and electronics sectors – to name a few.”

DAVE HOFFERBERT, PRESIDENT OF BOND
TECHNOLOGIES

Friction extrusion is a solid-state process requiring no external heat source. Heat is generated through friction created by rotation of the raw material relative to a die set while under axial load. As material is plasticized, it is forced to flow through the die. It can be used to form fully consolidated wire, rods, tubes, or non-circular metal shapes directly from a variety of precursor charges including metal powder, flake, machining waste (chips or swarf) or solid billet.

One version of the FE process is shown below. The spiral groove in the die face acts to pull billet material toward an opening in the center of the die.

FE (Friction Extrusion) Die Face

FE (Friction Extrusion) Process

FE creates new materials with new characteristics:

  • Very- to ultra-fine grain size
  • Low matrix dislocation density – high ductility
  • Consolidation of materials with high porosity, such as machining swarf
  • Larger sizes than other severe plastic deformation processes
  • Can produce solid rods or tubular products
  • Ability to disperse hard particles in a matrix without segregation

There are many applications for materials produced by FE, and the list is growing:

  • Creep resistant materials
  • Lightweight, high ductility magnesium and aluminum structures
  • Materials with enhanced thermal and electrical properties
  • Recycling of machining swarf into solid wire or rod
  • Direct consolidation of novel powder mixtures

Specific products that would benefit from this technology:

  • Electrical components with enhanced strength and conductivity
  • High-performance consumer products, such as golf clubs, bicycles and tennis rackets
  • Creep-resistant heat exchangers for power generation
  • Advanced magnets
  • Aluminum and magnesium rods or tubes for airframe structures
  • High ductility magnesium for automotive body components

1. Whalen, S., et al, “High Ductility Aluminum Alloy Made From Powder by Friction Extrusion,” Materialia, Vol. 6, June 2019, Elsevier.