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: A tube bending apparatus is provided for placing a plurality of bends in an elongated tube. The apparatus includes a position sensor for sensing at least one location on the tube for assessing the accuracy of the bends placed therein. The apparatus further includes a programmable bender having a bend die and a clamp die for securely engaging the tube and bending the tube through a selected degree of curvature. A collet assembly is operative to axially and rotationally position the tube for each sequential bend. A pressure die boost and a collet assembly are provided for exerting axial pressure on the tube to urge the tube into the bend. The amount of axial force is programmed and selectively controllable in response to sensed operating conditions. A lubricated mandrel is programmably operative to be placed inside the tube. The movement of the mandrel is programmable and the flow of lubrication therethrough is both programmable and condition responsive.

Abstract: A precision bending apparatus is provided for precisely bending tubes. The precision bending apparatus includes a preprogrammed bender for placing a selected sequence of bends in the tube. The apparatus further includes a position sensing means for sensing the precise position of locations on the bent portion of the tube. A control means is in communication with both the position sensing means and the bender, and is operative to alter the program of the bender based on data sensed by the position sensing means.