Method of extruding parts with captured fixture

A method of extruding a lead or lead alloy battery terminal of essentially pore-free material in which is captured a fixture comprised of a material harder than said lead or lead alloy, said fixture extending away from said battery terminal, said battery terminal having an essentially cylindrical boss and a radially extending arm element protruding from said boss, said method comprising:

• providing a first die element having a rigid body with a cavity having the desired final geometry of said battery terminal cylindrical boss and a first bore extending from said cavity, said first die element further comprising a passage extending radially from said bore and having a geometry corresponding to the desired external geometry of said radially extending arm element;
• providing a second die element disposed in contact with said first die element and defining therewith at least a portion of said cavity and a portion of said passage;
• positioning within said first bore a third die element for axial movement therewithin and having an essentially cylindrical external geometry corresponding to the geometry of said first bore;
• affixing said fixture of harder material to the end of the third die element facing toward said cavity;
• positioning within said cavity a billet of material comprised substantially of lead, said material having a first porosity;
• forcing said third die element and said fixture into contact with said billet thereby causing said material to extrude around said fixture affixed to said third die element to frictionally capture the fixture within said cylindrical boss and further causing said billet to extrude into said cavity to form said cylindrical boss, said forcing step further causing said billet to extrude into said passageway to form said radially extending arm element;
• densifying said material of said first porosity by said forcing step sufficiently so as to provide a second porosity less than said first porosity and thereby provide an essentially pore-free battery terminal;
• separating said first and second die element;
• ejecting said terminal and said fixture from said cavity;
• and
• detaching said fixture from said third die element.