Abstract: A composite tube and method of manufacture are provided. The composite tube is formed from a plurality of tube segments which are different from one another. The tube segments may differ in cross-sectional dimensions and/or material of manufacture. The tube segments are welded in end-to-end relationship to define a composite tube. The composite tube is then bent into a selected non-linear shape. Preferably, the welds are disposed at locations on tangents between adjacent bends. Bending forces and bending speed are altered from one bend to the next in view of anticipated strength and metallurgical characteristics of the particular tube segment in which the bend is being carried out.

Abstract: An exhaust muffler is provided with first and second internal plates formed to define an array of tubes and a reversing chamber. A pair of external shells are engaged to the internal plates and define one or more chambers surrounding the tubes defined by the internal plates. A pipe extends across the reversing chamber defined by the internal plates and to the outlet. A portion of the pipe may be perforated to enable expansion of exhaust gas into a high frequency tuning chamber.

Abstract: The subject invention is directed to a muffler formed from a plurality of stamped components. The stamped components include at least a pair of plates formed to define an array of tubes therein. The tubes include a plurality of unidirectional flow tubes each of which carries a portion of the exhaust gas flowing through the muffler. The plurality of unidirectional flow tubes communicate with an in-line expansion chamber defined within the muffler. The in-line expansion chamber enables exhaust gas flowing from the unidirectional flow tubes to expand significantly thereby contributing to noise attenuation. The muffler may further include at least one external shell defining a chamber which communicates with the tubes or the in-line expansion chamber.

Abstract: A reinforced stamped muffler is provided. The muffler includes a pair of internal plates secured in face-to-face relationship and formed to define an array of tubes and chambers therebetween. The chambers are provided with at least one array of reinforcing grooves. Larger chambers defined by the internal plates may include a first array of parallel reinforcing grooves and a second array of parallel reinforcing grooves extending transverse to and intersecting the end-most grooves in the first array. All of the grooves preferably extend into intersection with planar portions of the internal plates. The muffler further includes external shells formed to define larger chambers. The larger chambers of the external shells are formed with a major pattern of reinforcing undulations and a minor pattern of undulations or grooves superimposed thereon. The minor pattern preferably includes a parallel array of grooves with end most grooves in the parallel array being intersected by orthogonally extending grooves.