Abstract: Selectively reinforced blanks are used in a hydroforming process to produce completed components having a predetermined shape and sufficient structural integrity to perform their desired function. To reinforce those components, reinforcing patches are added to the blank prior to hydroforming. Planar patches can be bonded to planar blanks or arcuate patches can be bonded to tubular blanks. In so doing, the hydroforming process produces a complete component, which does not require additional manufacturing steps to reinforce it. Additionally, by selectively using the reinforcing patches, the overall weight of the component is not unduly increased.

Abstract: Tubular members for use in vehicle frames are easily and economically produced using a hydroforming process in which a high pressure fluid is presented to the interior of a tubular member, thus causing the tube to expand to meet the interior walls of a forming die. Tubular members can be formed having significant variations in their circumference, diameter along their lengths, or gage along their lengths by using a stamped blank having a predetermined shape which is formed into a preformed tube which roughly mirrors the shape of the desired finished tubular member.