Dual-phase hot extrusion of metals

A method of dual-phase hot metal extrusion comprising the steps of:

• a) providing a load carrier made of a first metal material, wherein the load carrier comprises a load end, a blind end, and at least one load chamber having a depth extending axially from the load end towards the blind end, wherein the at least one load chamber comprises a load material and a void space, wherein the load material comprises a second metal material, the second metal material having a lower melting point than the melting point of the first metal material, and wherein the void space is configured to accommodate at least a portion of the second metal material in its molten form when the load carrier is heated;
• b) heating the load carrier to a temperature above the melting point of the second metal material but below the melting point of the first metal material to form a solid load carrier comprising a liquid metal in the at least one load chamber;
• c) providing an extrusion tool comprising a first extrusion die, a second extrusion die, and a cooling cavity, wherein an extrusion transfer channel extends from the first extrusion die through the cooling cavity to the second extrusion die of the extrusion tool, wherein a portion of the extrusion transfer channel extending through the cooling cavity comprises at least one opening located between the first extrusion die and the second extrusion die, and wherein the cooling cavity comprises at least one cooling port configured to provide a cooling agent at the at least one opening of the extrusion transfer channel;
• d) providing a cooling agent through the at least one cooling port;
• and
• e) continuously extruding the heated load carrier, wherein the load carrier is extruded through the first extrusion die, contacted with water, and extruded through the second extrusion die inside the container of an extrusion press.