Abstract: A method of forming metal castings, including positioning a first end of a structural member in a first mold cavity and a second end of the structural member in a second mold cavity. The first and second mold cavities being fluidly coupled to a reservoir of molten metal. Applying a main pressure to the molten metal in the reservoir to force the molten metal into the first mold cavity and the second mold cavity. Then, applying a first auxiliary pressure to the first mold cavity and a second auxiliary pressure to the second mold cavity to densify the casting formed in the first mold cavity and the second mold cavity. Also, a method for casting including maintaining a main pressure at or less than an initial, mold-filling pressure after first and second mold cavities have been filled. Additionally, a method for detecting whether a first mold cavity is sufficiently filled with molten metal by monitoring a moveable element.

Abstract: A hybrid component for lightweight, structural uses, including a steel member formed of a high strength steel; and a cast coupling member cast on a portion of the steel member by casting-in-place a semi-solid aluminum about the portion of the steel member, thereby positively and rigidly securing the coupling member to the steel member. A method of forming a hybrid component for lightweight, structural uses, including: forming a steel member formed of a high strength steel into a predetermined configuration; and casting a coupling member on a portion of the steel member by casting-in-place a semi-solid aluminum about the portion of the steel member, thereby positively and rigidly securing the coupling member to the steel member.

Abstract: A method of forming metal castings includes positioning a first end of a structural member in a first mold cavity and a second end of the structural member in a second mold cavity. The first and second mold cavities are fluidly coupled to a reservoir of molten metal. A main pressure is applied to the molten metal in the reservoir to force the molten metal into the first and second mold cavities. First and second auxiliary pressures are applied to the first and second mold cavities to densify the castings formed in the first and second mold cavities. Another method for casting includes maintaining a main pressure at or less than an initial, mold-filling pressure after the first and second mold cavities have been filled. Additionally, a method for detecting whether a first mold cavity is sufficiently filled with molten metal includes monitoring a moveable element.

Abstract: The invention is intended to improve a tool arrangement and method for explosive forming of a workpiece by means of gas explosion, in which the workpiece is arranged in a intake area of a moulding tool, wherein the intake area is at least partially filled with liquid and the explosion is triggered by means of ignition of an explosive gas mixture, to the effect that the tool arrangement and the method are suitable and simplified for mass production. This object is solved by means of a tool arrangement and a method for explosive forming of a workpiece by means of gas explosion, in which the workpiece is arranged in a intake area of a moulding tool, wherein the intake area is at least partially filled with liquid and the explosion is triggered by means of ignition of an explosive gas mixture, in which the explosive gas mixture is provided at least partially above the surface of the liquid before the ignition.

Abstract: A metal forming die includes a first die half and a second die half moveable relative to the first die half. The first and second die halves define a die cavity when the second die half is in a closed position. A transducer is operable to vibrate the first die half during metal forming.

Abstract: A hot forming die that includes a first die and a second die. The first die has a first die structure that is formed of a tool steel. The first die structure has a first die surface and a plurality of first cooling apertures. The first die surface has a complex shape. The first cooling apertures are spaced apart from the die surface by a first predetermined distance. The second die has a second die surface. The first and second die surfaces cooperate to form a die cavity. Related methods for forming a hot forming die and for hot forming a workpiece are also provided.

Abstract: An explosion forming apparatus (10) that preferably utilizes a shock wave (42) directed along a work piece (12) to progressively conform the work piece to a contour die cavity (44).

Abstract: A motor vehicle frame includes a pair of longitudinal frame members. A cross member is provided to maintain the frame members in a spaced apart condition. The cross member has a first end configured to mount to a first one of the longitudinal frame members and a second end configured to engage a steering gear housing. The second end sandwiches steering gear housing as the second end is fastened to a second one of the frame members.

Abstract: A method of forming metal castings, including positioning a first end of a structural member in a first mold cavity and a second end of the structural member in a second mold cavity. The first and second mold cavities being fluidly coupled to a reservoir of molten metal. Applying a main pressure to the molten metal in the reservoir to force the molten metal into the first mold cavity and the second mold cavity. Then, applying a first auxiliary pressure to the first mold cavity and a second auxiliary pressure to the second mold cavity to density the casting formed in the first mold cavity and the second mold cavity. Also, a method for casting including maintaining a main pressure at or less than an initial, mold-filling pressure after first and second mold cavities have been filled. Additionally, a method for detecting whether a first mold cavity is sufficiently filled with molten metal by monitoring a moveable element.

Abstract: A traditional twist beam axle found in a vehicle includes a twist beam with a separate torsion beam or a hollow tube formed into an inverted U shape that acts as both the twist beam and the torsion beam.

Abstract: A method of hydroforming a tubular structure of varying diameter along its longitudinal axis, comprising the formation of a tubular blank member by welding together, at their periphery, tubes of different diameters using electromagnetic pulse welding.

Abstract: A method of hydroforming a tubular structure of varying diameter along its longitudinal axis, comprising the formation of a tubular blank member by welding together, at their periphery, tubes of different diameters using electromagnetic pulse welding.