Abstract: Devices and processes for performing shear-assisted extrusion include a rotatable extrusion die with a scroll face configured to draw plasticized material from an outer edge of a billet generally perpendicularly toward an extrusion orifice while the extrusion die assembly simultaneously applies a rotational shear and axial extrusion force to the billet.

Abstract: Reactive coating processes are provided that can include providing a coating material, reacting the coating material to form a shell about the coating material, contacting the shelled coating material with a substrate to be coated, depositing the coating material from within the shelled coating material on the substrate, and removing the shells from the substrate. Coating materials may be deposited upon a substrate to be coated and reacted to form a shell about the coating material. The coating materials can be particles and a shell can be formed about each of the individual particles.

Abstract: An extrusion apparatus and process are disclosed that produce high-performance extrusion structures. The extrusion apparatus includes a shear tool that applies a rotational shear force and an axial extrusion force to the face of a billet material that plasticizes the billet material. Plasticized material is extruded through an extrusion die along the length of the inner bore of the shear tool which yields hollow and solid extrusion structures. The process refines the microstructures of the extrusion structures and extrusion materials.