Abstract: A component forming tool for forming a component from a blank includes a die forming shell for forming the component from the blank. A first shell portion of the die forming shell is located on a first set of support elements and a second shell portion is located on a second set of support elements. The tool includes at least one induction heating coil for induction heating of a workpiece disposed within a cavity formed by the first and second shell portions. The first set of support elements include multi-material support elements having at least two layers of different materials and the second set of support elements include multi-material support elements having at least two layers of different materials.

Abstract: Assisted magnetic forming uses a magnetic field to assist in the forming or molding of metallic and non-metallic materials. For example, such a forming process may form a blank of ferromagnetic metals like high-strength steel and high-hard armor, non-ferromagnetic metals like aluminum and magnesium, as well as non-metals like ceramics, plastics, and fiber-reinforced composites into formed or molded parts. The magnetic field is generated to partially or completely saturate the blank during the forming process, which increases the blank's formability and/or moldability while in the presence of the magnetic field.

Abstract: A component forming tool for forming a component from a blank includes a die forming shell for forming the component from the blank. A first shell portion of the die forming shell is disposed at a first set of support elements and a second shell portion is disposed at a second set of support elements. The tool includes at least one induction heating coil for induction heating of a workpiece disposed within a cavity formed by the first and second shell portions. The first set of support elements may be configured to detachably engage with respective base support elements of the component forming tool, with the first set of support elements keyed to engage the base support elements to limit lateral movement of the first shell portion at the base support elements. The first set of support elements may include at least two layers of different materials.

Abstract: A method of forming and quenching a product via electrically heating includes providing tools that have been electrically heated, providing a die forming shell for supporting a component and for defining a final shape of a formed product formed from the component, and providing a support structure for supporting the die forming shell during the heating of the component or tools. Two portions of the die forming shell are joined together so that an inner surface of the two portions cooperate to form a cavity that defines the shape of the formed product. The component is formed into the formed product, whereby the component is (a) heated before the formed product is formed and/or (b) heated while the formed product is formed. The formed product is quenched via conductive quenching through the die forming shell by at least one of water and a gas.

Abstract: A heat assisted friction stir welding system and fastener for use therewith allows the joining a variety of dissimilar materials, including joining composites and plastics to metal, in which the fastener becomes part of the bond. The fastener can be constructed from multiple materials, allowing for the joining of dissimilar metals. Heating the materials to be joined reduces the clamping force and torque required by the friction stir weld process. The result is a bond that is stronger with less energy input.

Abstract: A component forming tool for forming a component from a blank includes a die forming shell having a first shell portion disposed at a first set of support elements and a second shell portion disposed at a second set of support elements. A first fluid line has a plurality of first fluid discharge ports at or near the first shell portion. A second fluid line has a plurality of second fluid discharge ports at or near respective ones of the first fluid discharge ports that are located in between the support elements. The component forming tool provides pressurized fluid in the first and second fluid lines and the pressurized fluids are discharged from the respective first and second fluid discharge ports. The fluid discharged from the second fluid line mixes with the fluid discharged from the first fluid line to cool the first shell portion.

Abstract: A method of forming a product via induction heating and forming of the product includes providing an induction heating coil for induction heating of a component and providing a die forming shell for supporting the component and for defining the final shape of a formed product formed from the component. The die forming shell includes a metallic material. A support structure is provided for supporting the die forming shell during the induction heating of the component. The support structure includes a metallic material. The support structure includes insulating portions to limit or substantially preclude inducement of electrical current through the support structure during the induction heating process. The component is inductively heated along its length while the component is in the die forming shell. The component is at least one of (a) heated before the formed product is formed and (b) heated while the formed product is formed.

Abstract: A component forming tool for forming a component from a blank includes a die forming shell having a first shell portion disposed at a first set of support elements and a second shell portion disposed at a second set of support elements. A first fluid line has a plurality of first fluid discharge ports at or near the first shell portion. A second fluid line has a plurality of second fluid discharge ports at or near respective ones of the first fluid discharge ports that are located in between the support elements. The component forming tool provides pressurized fluid in the first and second fluid lines and the pressurized fluids are discharged from the respective first and second fluid discharge ports. The fluid discharged from the second fluid line mixes with the fluid discharged from the first fluid line to cool the first shell portion.

Abstract: A component forming system has an induction heating coil for induction heating of a component and a die forming shell for supporting the component and for defining the final shape of the formed product. A support structure for supporting the die forming shell during the induction heating of the component may be formed of a metallic material, and/or may include insulating elements to limit or substantially preclude inducement of electrical current through the support structure during the induction heating process. The die forming shell may be formed of a metallic material and/or may include insulating elements to limit or substantially preclude inducement of electrical current through the support structure during the induction heating process.