Microextrusion

Microextrusion is a microforming extrusion process performed at the submillimeter range. Like extrusion, metal is pushed through a die orifice, but the resulting product's cross section can fit through a 1mm square. Several microextrusion processes have been developed since microforming was envisioned in 1990. Forward (ram and billet move in the same direction) and backward (ram and billet move in the opposite direction) microextrusion were first introduced, with forward rod-backward cup and double cup extrusion methods developing later. Regardless of method, one of the greatest challenges of creating a successful microextrusion machine is the manufacture of the die and ram. "The small size of the die and ram, along with the stringent accuracy requirement, needs suitable manufacturing processes." Additionally, as Fu and Chan pointed out in a 2013 state-of-the-art technology review, several issues must still be resolved before microextrusion and other microforming technologies can be implemented more widely, including deformation load and defects, forming system stability, mechanical properties, and other size-related effects on the crystallite (grain) structure and boundaries.

Microextrusion is an outgrowth of microforming, a science that was in its infancy in the early 1990s. In 2002, Engel et al. expressed that up to that point, only a few research experiments involving micro-deep drawing and extruding processes had been attempted, citing limitations in shearing on billets and difficulties in tool manufacturing and handling. By the mid- to late 2000s, researchers were working on issues such as billet flow, interfacial friction, extrusion force, and size effects, "the deviations from the expected results that occur when the dimension of a workpiece or sample is reduced." Most recently, research into using ultrafine-grained material at higher formation temperatures and applying ultrasonic vibration to the process has pushed the science further. However, before bulk production of microparts such as pins, screws, fasteners, connectors, and sockets using microforming and microextrusion techniques can occur, more research into billet production, transportation, positioning, and ejection are required.

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