Abstract: In the present invention, at least one tubular blank and at least one article such as a metal stamping, to be attached to a hydroformed part, are loaded into a die. The tube is hydroformed using typical methods. The article is positioned in the die such that, when the tube is hydroformed, the final hydroformed tube contacts the article at least at a point. Attachment means, such as a laser welder, are provided with access to the contact point between the article and the hydroformed tube so that a tack weld or other attachment can be made between the article and the hydroformed tube while still in the closed die. The hydroformed tube and attached article are then removed as a joint assembly from the die.
Abstract: In the present invention, at least one tubular blank and at least one article such as a metal stamping, to be attached to a hydroformed part, are loaded into a die. The tube is hydroformed using typical methods. The article is positioned in the die such that, when. the tube is hydroformed, the final hydroformed tube contacts the article at least at a point. Attachment means, such as a laser welder, are provided with access to the contact point between the article and the hydroformed tube so that a tack weld or other attachment can be made between the article and the hydroformed tube while still in the closed die. The hydroformed tube and attached article are then removed as a joint assembly from the die.
Abstract: In the present invention a tubular blank and an article such as a bushing to be assembled are loaded into a die. The tube is hydroformed using typical methods and, while the blank is still pressurized, a punch pierces a hole in the tube. The punch also has an article loaded onto it and, as the punch advances, the article is pushed into the tube through the pierced hole. The punch continues to advance such that it pierces a hole in the opposite side of the tube. The punch then retracts leaving the bushing in the tube. The article may alternately be inserted by means separate from the punch.