US20120018112A1 - Method and apparatus for forming a liquid-forged article - Google Patents
Method and apparatus for forming a liquid-forged article Download PDFInfo
- Publication number
- US20120018112A1 US20120018112A1 US13/260,717 US201013260717A US2012018112A1 US 20120018112 A1 US20120018112 A1 US 20120018112A1 US 201013260717 A US201013260717 A US 201013260717A US 2012018112 A1 US2012018112 A1 US 2012018112A1
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- United States
- Prior art keywords
- aspect ratio
- high aspect
- melt
- cavity
- punch
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D18/00—Pressure casting; Vacuum casting
- B22D18/02—Pressure casting making use of mechanical pressure devices, e.g. cast-forging
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/06—Permanent moulds for shaped castings
- B22C9/067—Venting means for moulds
Definitions
- the punch 22 is moved relative to the die cavity 41 to contact the melt 52 in the die cavity 41 , 104 , such that the melt 52 enters the recess 46 in the retaining pin 44 to form a retaining portion 36 in the liquid-forged article 30 .
- the melt 52 is also forced to flow and enter the high aspect ratio cavities 24 of the punch 22 . This is preferably achieved by bringing the punch 22 towards the die cavity 41 as indicated by the arrow 60 .
- the ram down speed or relative speed between the punch 22 and the die cavity 41 is preferably less than 0.5 ms ⁇ 1 to allow for thorough filling of the cavities 24 with the melt 52 .
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Forging (AREA)
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.
Description
- The invention relates to a method and an apparatus for forming a liquid-forged article and particularly, though not exclusively, to forming a liquid-forged near net-shape article having features with high aspect ratio.
- Articles having features with high aspect ratio are conventionally made by methods including machining, extrusion, forging, or casting a metal such as aluminium (Al). Machining is a process that produces articles with high tolerance control and good surface finishing. However, it is time consuming and expensive and results in a large amount of material wastage, making it unsuitable as a process for mass production. Extrusion and forging are processes that can produce articles with good structural integrity. However, traditional extrusion and forging are unable to form articles requiring a high density of features having high aspect ratio, such as heat sinks having fins and pins in close proximity as shown in
FIGS. 1 and 2 . - Die casting (high and low pressure) is a competing technology with some form of indirect pressure during material solidification that is widely used in industry. Gravity or die casting allows articles to solidify under little or no pressure. However, articles made by gravity or die casting methods often suffer from limitations such as porosity in the article structure, for example due to high turbulence of the in-gate in high pressure die casting, or gas entrapment in gravity casting, resulting in poor mechanical properties. Die casting is also unable to form net-shape articles having high-aspect ratio features without distortion, for example, the round heat sink with high aspect ratio fins 10 as shown in
FIG. 1 where the height (h) to thickness (t) ratio of eachfin 10 is greater than 40 to 1, i.e., h:t>40:1. Furthermore, material choice is naturally limited to only casting alloys, whereas for an article to be used as a thermal management component such as a heat sink, it is desirable for it to be formed from low silicon wrought Al alloys or pure Al due to their enhanced thermal dissipating performance. However, these materials cannot be successfully cast due to shrinkage defects resulting from the casting process. - Squeeze casting or liquid forging forms articles using at least partially molten metal under direct pressure in a punch and die set. Improved article tolerances with minimized material distortion and shrinkage defects can be obtained. However, issues of porosity and incomplete part formation due to gas entrapment still remain, especially in the formation of articles having high aspect ratio features. This is even more of a problem when the high aspect ratio features are required to be relatively small in size, for example, where the thickness of the feature is 2 mm or less, as porosities in such small features can make up a substantial proportion of the feature to result in material breakage and/or part failure.
- According to a first exemplary embodiment, there is provided 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.
- The method may further comprise relatively moving the punch away from the die cavity while retaining the article in the die cavity. The article is preferably 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.
- According to a second exemplary aspect, there is provided an apparatus for forming a liquid-forged article. The apparatus comprises 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 be released from the high aspect ratio cavity.
- For both aspects, air is preferably released through a gas exhaust passage defined by the air vent insert with the high aspect ratio cavity. Air may 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.
- The air vent insert preferably 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. The insert portion may be tapered with a decreasing cross-sectional area as it extends into the high aspect ratio cavity.
- The air vent insert may be provided with at least one gas vent, the gas vent being in fluid communication with the gas exhaust passage. The at least one gas vent is preferably provided in the head portion.
- The gas exhaust passage is preferably dimensioned to prevent excessive melt flow therein for preventing clogging of the gas exhaust passage by solidified melt. The gas exhaust passage may have a length ranging between 2 mm and 6 mm, with a gap tolerance of at least 20 mm between the air vent insert and a wall of the high aspect ratio cavity.
- The apparatus may further comprise 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. The retaining pin preferably comprises a recess for solidifying the melt therein such to form a retaining portion of the article within the recess.
- The apparatus may comprise a plurality of high aspect ratio cavities and a corresponding plurality of air vent inserts. The plurality of air vent inserts may be provided individually.
- According to a third exemplary aspect, there is provided a liquid-forged article having high aspect ratio features obtained by forming with the method of the first aspect.
- According to a fourth exemplary aspect, there is provided a liquid-forged article having high aspect ratio features obtained using the apparatus of the second aspect.
- In order that the invention may be fully understood and readily put into practical effect there shall now be described by way of non-limitative example only exemplary embodiments of the present invention, the description being with reference to the accompanying illustrative drawings.
- In the drawings:
-
FIG. 1( a) is a schematic side view illustration of an article having high aspect ratio features, i.e., a round heat sink having tapered fins; -
FIG. 1( b) is a schematic top view illustration of the heat sink ofFIG. 1( a); -
FIG. 2 is schematic perspective illustrations of examples of typical articles having high aspect ratio features, i.e., heat sinks with tapered fins, pins and radial fins; -
FIG. 3 is a flow chart of an exemplary method of forming liquid-forged articles; -
FIG. 4 is a schematic cross-sectional side view illustration of an exemplary apparatus for forming liquid-forged articles at a forming step of introducing a melt into a die cavity; -
FIG. 5 is the apparatus ofFIG. 4 at a forming step of moving a punch into the die cavity; -
FIG. 6 is a schematic cross-sectional side view illustration of air vent inserts in the punch of the apparatus ofFIG. 4 ; -
FIG. 7 is a close-up view of an air vent insert ofFIG. 6 ; -
FIG. 8 is the apparatus ofFIG. 4 at a forming step of relatively moving the punch away from the die cavity; -
FIG. 9 is the apparatus ofFIG. 4 at a forming step of ejecting a formed article from the die cavity; -
FIG. 10 is a schematic side view illustration of removal of a portion of the formed article; -
FIG. 11 is a schematic side view illustration of high aspect ratio features formed with flash; -
FIG. 12 is perspective photographic illustrations of exemplary articles formed by the exemplary method and apparatus of the present invention; -
FIG. 13 (a) is a micrograph of material grain size obtained by conventional casting; and -
FIG. 13( b) is a micrograph of material grain size obtained by the present invention. - As shown in
FIGS. 3 to 10 , an exemplary method 100 andapparatus 20 are provided for forming a liquid-forged article having at least one high aspect ratio feature with height to width ratio preferably greater than 40:1. - The
apparatus 20 comprises apunch 22 having at least one highaspect ratio cavity 24 for forming a high aspect ratio feature 34 in a liquid-forgedarticle 30. For articles having a plurality of high aspect ratio features 34, a corresponding plurality of highaspect ratio cavities 24 are provided in thepunch 22. Each highaspect ratio cavity 24 has an internal cavity shape corresponding to a desired feature to be formed in thearticle 30, such as a pin or a fin as shown in the heat sinks ofFIG. 2 . The highaspect ratio cavities 24 may be defined by corresponding highaspect ratio features 25 provided in thepunch 22. - The
apparatus 20 further comprises a bottom puller or retainingpin 44 disposed in adie 42 for part retention and ejection. In an exemplary embodiment, the bottom puller or retainingpin 44 is provided with a trapezoidally-shaped recess 46 for retaining a formed article using a dovetail fit. Thepunch 22 and die 42 are preferably oriented and provided as atop punch 22 and abottom die 42. - As shown in
FIG. 4 , in a first step of the exemplary method 100, amelt 52 comprising an at least partially molten material for forming thearticle 30 is introduced into adie cavity 41 of the die 42, 102, for example, via alaunder 50. The melt temperature may range from 710° C. to 750° C., depending on the material chosen. - Next, as shown in
FIG. 5 , thepunch 22 is moved relative to thedie cavity 41 to contact themelt 52 in thedie cavity 41, 104, such that themelt 52 enters therecess 46 in the retainingpin 44 to form a retainingportion 36 in the liquid-forgedarticle 30. Themelt 52 is also forced to flow and enter the highaspect ratio cavities 24 of thepunch 22. This is preferably achieved by bringing thepunch 22 towards thedie cavity 41 as indicated by thearrow 60. The ram down speed or relative speed between thepunch 22 and thedie cavity 41 is preferably less than 0.5 ms−1 to allow for thorough filling of thecavities 24 with themelt 52. - Virtually no air bubbles are trapped in or by the
melt 52 that enters and fills the highaspect ratio cavities 24 as air is released or allowed to escape via air vent inserts 80 provided in thepunch FIG. 6 , each highaspect ratio cavity 24 is provided with its ownair vent insert 80 in thepunch 22 to allow air to be released from each highaspect ratio cavity 24. This ensures that all thecavities 24 are fully filled by themelt 52 to virtually eliminate porosity or incomplete part formation in thearticle 30 when formed. - Each
air vent insert 80 preferably has ahead portion 82 and aninsert portion 84. Thehead portion 82 and theinsert portion 84 may be integral with each other. Thehead portion 82 may be accommodated in a correspondingly shapedrecess 23 in thepunch 22, and is preferably configured to position theair vent insert 80 relative to its corresponding highaspect ratio cavity 24. Theinsert portion 84 is configured to extend into the highaspect ratio cavity 24, so that theair vent insert 80 has a generally T-shaped cross-section, as shown hatched inFIG. 7 . Accordingly, theair vent insert 80 may comprise, for example, a disc-shapedhead portion 82 with a rod-shapedinsert portion 84 for forming a high aspect ratio pin, or an elongate, substantiallyrectangular head portion 82 with an elongate, substantiallyrectangular insert portion 84 for forming a high aspect ratio fin, depending on the desired high aspect ratio feature to be formed. - The
insert portion 84 is preferably tapered with a decreasing cross-sectional area as it extends into the highaspect ratio cavity 24, such that theinsert portion 84 defines agas exhaust passage 86 with the highaspect ratio cavity 24. Eachair vent insert 80 is preferably also provided with at least onegas vent 88 in thehead portion 80, thegas vent 88 being in fluid communication with thegas exhaust passage 86. Thegas exhaust passage 86 and thegas vent 88 allow air to escape from thecavity 24 as themelt 52 enters the highaspect ratio cavity 24 in the direction shown by thearrow 66 inFIG. 7 . - The
air vent insert 80 is preferably made of a metal of high heat conductivity, such as a copper-based material, so that as themelt 52 comes into contact with theair vent insert 80, themelt 52 is rapidly cooled. Rapid cooling of themelt 52 prevents excessive flow of themelt 52 into thegas exhaust passage 86 that can lead to choking or clogging of thegas exhaust passage 86 orgas vent 88. Accordingly, thegas exhaust passage 86 should be dimensioned to prevent excessive melt flow therein so as to avoid clogging by solidifiedmelt 52, while sufficiently allowing air to be released. To that end, thegas exhaust passage 86 may have a length ranging between 2 mm and 6 mm along thecavity 24, with a gap tolerance of at least 20 μm between theinsert portion 84 and awall 26 of the highaspect ratio cavity 24. - The
punch 22 is configured to exert a forming or direct pressure of between 50 MPa and 120 MPa on themelt 52 while themelt 52 solidifies in the highaspect ratio cavities melt 52 under direct pressure of thepunch 22 results in formation of a near net-shape article 30 having high aspect ratio features 34 with virtually no porosity or shrinkage defects. - After the
melt 52 has solidified, thepunch 22 is moved relative to thedie cavity 41 to separate the liquid-forgedarticle 30 from thepunch 22. For example, as shown inFIG. 8 , thepunch 22 may be retracted from the die 42 as indicated by thearrow 62, leaving behind the liquid-forgedarticle 30 in thedie cavity 41. Thepunch 22 can be retracted without the formedarticle 30 sticking to thepunch 22 because of the dovetailing fit between therecess 46 in the retainingpin 44 and the retainingportion 36 formed in thearticle 30. The liquid-forgedarticle 30 is then removed or ejected from thedie cavity 41 by relative movement between the retainingpin 44 and the die 42 until the formedarticle 30 is clear of thedie cavity 41. The relative movement may preferably be achieved by moving the retainingpin 44 into thedie cavity 41 in the direction indicated by thearrow 64 inFIG. 9 so that the formedarticle 30 is pushed out of thedie cavity 41. - The
article 30 may be finished by machining or cutting off the retainingportion 36, as indicated by the dotted line inFIG. 10( a) to result in the formation of a near net-shape liquid forgedarticle 30 havingfeatures 34 with high aspect ratio as shown inFIG. 10( b).FIG. 11 shows close-ups of exemplary high aspect ratio features 70, 72 formed withflashes melt 52 in the gas exhaust passage 27. Theflashes 71 of athicker feature 70 as shown inFIG. 11( a) may be removed by sand blasting or tumbling. For athinner feature 72 as shown inFIG. 11( b) that may not be rigid enough to withstand the forces of sand blasting or tumbling, theflashes 73 may be cut or trimmed away. - Exemplary liquid-forged articles such as
heat sinks 90 having highaspect ratio fins 92 or pins 94 formed by the exemplary method 100 andapparatus 20 described above are shown inFIG. 12 . As can be seen inFIG. 13 (b), the microstructural grain size of the liquid-forged articles is significantly smaller than the grain size of articles formed by conventional casting shown inFIG. 13( a). Smaller grain sizes together with virtually no porosity result in improved toughness of the liquid-forged articles over conventionally cast articles, thereby strengthening the high-aspect ratio features formed. - Whilst there has been described in the foregoing description exemplary embodiments of the present invention, it will be understood by those skilled in the technology concerned that many variations in details of design, construction and/or operation may be made without departing from the present invention. For example, where a plurality of high
aspect ratio cavities 24 are provided in thepunch 22, the corresponding plurality of air vent inserts 80 may be provided individually for ease of air release or may alternatively be provided as an integral unit comprising a plurality ofinsert portions 84 disposed on asingle head portion 82 for reduced tooling costs. The plurality of high aspect ratio cavities 24 (and their corresponding air vent inserts 80) may or may not be identical, depending on the desired high aspect ratio features 34 to be formed. The liquid-forgedarticle 30 may or may not be symmetrical.
Claims (19)
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.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US13/260,717 US20120018112A1 (en) | 2009-03-27 | 2010-03-09 | Method and apparatus for forming a liquid-forged article |
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US16406009P | 2009-03-27 | 2009-03-27 | |
PCT/SG2010/000077 WO2010110742A1 (en) | 2009-03-27 | 2010-03-09 | Method and apparatus for forming a liquid-forged article |
US13/260,717 US20120018112A1 (en) | 2009-03-27 | 2010-03-09 | Method and apparatus for forming a liquid-forged article |
Publications (1)
Publication Number | Publication Date |
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US20120018112A1 true US20120018112A1 (en) | 2012-01-26 |
Family
ID=42781262
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US13/260,717 Abandoned US20120018112A1 (en) | 2009-03-27 | 2010-03-09 | Method and apparatus for forming a liquid-forged article |
Country Status (6)
Country | Link |
---|---|
US (1) | US20120018112A1 (en) |
EP (1) | EP2411173B1 (en) |
CN (1) | CN102438772B (en) |
SG (1) | SG174584A1 (en) |
TW (1) | TWI613018B (en) |
WO (1) | WO2010110742A1 (en) |
Cited By (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
USD800676S1 (en) * | 2016-08-30 | 2017-10-24 | Abl Ip Holding Llc | Heat sink |
USD800677S1 (en) * | 2016-08-30 | 2017-10-24 | Abl Ip Holding Llc | Heat sink |
USD822624S1 (en) * | 2016-08-30 | 2018-07-10 | Abl Ip Holding Llc | Heat sink |
Families Citing this family (3)
Publication number | Priority date | Publication date | Assignee | Title |
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CN106890981A (en) * | 2015-12-21 | 2017-06-27 | 龙德压铸五金(深圳)有限公司 | A kind of aluminium bag jet device and its application method |
CN105903924B (en) * | 2016-06-14 | 2017-11-28 | 北京交通大学 | A kind of preparation facilities and method of composite bar |
CN108817364A (en) * | 2018-07-13 | 2018-11-16 | 安徽思源三轻智能制造有限公司 | A kind of liquid forging machine melt is uniformly injected into device |
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- 2010-03-09 WO PCT/SG2010/000077 patent/WO2010110742A1/en active Application Filing
- 2010-03-09 US US13/260,717 patent/US20120018112A1/en not_active Abandoned
- 2010-03-09 SG SG2011069929A patent/SG174584A1/en unknown
- 2010-03-09 EP EP10756433.8A patent/EP2411173B1/en active Active
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Also Published As
Publication number | Publication date |
---|---|
TW201039941A (en) | 2010-11-16 |
CN102438772A (en) | 2012-05-02 |
CN102438772B (en) | 2014-05-28 |
TWI613018B (en) | 2018-02-01 |
EP2411173A4 (en) | 2014-07-30 |
EP2411173B1 (en) | 2020-11-18 |
WO2010110742A1 (en) | 2010-09-30 |
EP2411173A1 (en) | 2012-02-01 |
SG174584A1 (en) | 2011-10-28 |
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