Method and apparatus for forming a liquid-forged article

Abstract

A method of forming a liquid-forged article. The method comprises introducing a melt into a die cavity; moving a punch relative to the die cavity such that the melt enters at least one high aspect ratio cavity in the punch and air is released via at least one air vent insert in the punch; and exerting a forming pressure on the melt while the melt solidifies in the high aspect ratio cavity.

1 . A method of forming a liquid-forged article, the method comprising:
 introducing a melt into a die cavity;   moving a punch elative to the die cavity such that the melt enters at least one high aspect ratio cavity in the punch and air is released via at least one air vent insert in the punch; and   exerting a forming pressure on the melt while the melt solidifies in the high aspect ratio cavity.   
     
     
         2 . The method of  claim 1 , further comprising relatively moving the punch away from the die cavity while retaining the article in the die cavity. 
     
     
         3 . The method of  claim 2 , wherein the article is retained in the die cavity by forming a retaining portion of the article within a recess provided in a retaining pin disposed in a die containing the die cavity. 
     
     
         4 . The method of  claim 1 , wherein air is released through a gas exhaust passage defined by the air vent insert with the high aspect ratio cavity. 
     
     
         5 . The method of  claim 4 , wherein air is further released through at least one gas vent provided in the air vent insert, the gas vent being in fluid communication with the gas exhaust passage. 
     
     
         6 . An apparatus for forming a liquid-forged article, the apparatus comprising:
 a die cavity for receiving a melt; and   a punch configured to exert a forming pressure on the melt, the punch comprising a least one high aspect ratio cavity for receiving the melt therein and at least one air vent insert for allowing air to be released from the high aspect ratio cavity.   
     
     
         7 . The apparatus of  claim 6 , wherein the air vent insert defines a gas exhaust passage with the high aspect ratio cavity. 
     
     
         8 . The apparatus of  claim 6 , wherein the air vent insert comprises a head portion and an insert portion, the head portion being configured for positioning the air vent insert relative to the high aspect ratio cavity, and the insert portion being configured for extending into the high aspect ratio cavity. 
     
     
         9 . The apparatus of  claim 8 , wherein the insert portion is tapered with a decreasing cross-sectional area as it extends into the high aspect ratio cavity. 
     
     
         10 . The apparatus of  claim 7 , the air vent insert defines a gas exhaust passage with the high aspect ratio cavity, and wherein the air vent insert is provided with at least one gas vent, the gas vent being in fluid communication with the gas exhaust passage. 
     
     
         11 . The apparatus of  claim 10 , wherein the air vent insert comprises a head portion and an insertion e head portion being configured for positioning the air vent insert relative to the high aspect ratio cavity, and the insert portion being configured for extending into the high aspect ratio cavity, and wherein the at least one gas vent is provided in the head portion. 
     
     
         12 . The apparatus of  claim 7 , wherein the gas exhaust passage is dimensioned to prevent excessive melt flow therein for preventing clogging of the gas exhaust passage by solidified melt. 
     
     
         13 . The apparatus of  claim 7 , wherein the gas exhaust passage has a length ranging between 2 mm and 6 mm and wherein there is a gap tolerance of at least 20 mm between the air vent insert and a wall of the high aspect ratio cavity. 
     
     
         14 . The apparatus of  claim 6 , further comprising a retaining pin for retaining the article in the die cavity while relatively moving the punch away from the die cavity, the retaining pin being disposed in a die containing the die cavity. 
     
     
         15 . The apparatus of  claim 14 , wherein the retaining pin comprises a recess for solidifying the melt therein such to form a retaining portion of the article within the recess. 
     
     
         16 . The apparatus of  claim 6 , further comprising a plurality of high aspect ratio cavities and a corresponding plurality of air vent inserts. 
     
     
         17 . The apparatus of  claim 16 , wherein the plurality of air vent inserts are provided individually. 
     
     
         18 . A liquid-forged article having high aspect ratio features obtained by forming with a method comprising:
 introducing a melt into a die cavity;   moving a punch relative to the die cavity such that the melt enters at least one high aspect ratio cavity in the punch and air is released via at least one air vent insert in the punch; and   exerting a forming pressure on the melt while the melt solidifies in the high aspect ratio cavity.   
     
     
         19 . A liquid-forged article having high aspect ratio features obtained using an apparatus comprising:
 a die cavity for receiving a melt; and   a punch configured to exert a forming pressure on the melt, the punch comprising at least one high aspect ratio cavity for receiving the melt therein and at least one air vent insert for allowing air to he released from the high aspect ratio cavity.