Abstract: A method for manufacturing a pipe includes: press-forming a plate member into a U shape; and press-forming the plate member formed into the U shape into an O shape. The pipe includes a pipe body and a tapered part tilted radially inward and protruding from one end of the pipe body. Before the plate member is press-formed into the U shape, a boundary between a portion of the plate member corresponding to the pipe body and a portion of the plate member corresponding to the tapered part is pressed from a surface of the plate member corresponding to an inner peripheral surface of the pipe to bend the portion of the plate member corresponding to the tapered part toward the surface of the plate member corresponding to the inner peripheral surface of the pipe.

Abstract: A vehicle reinforcement beam is roll formed from a metal sheet to provide a multi-tubular reinforcement beam that includes two adjacent tubular sections that share a common center wall. The outer sections the metal sheet extend from opposing ends of the common center wall and are formed to enclose the adjacent tubular sections. An edge portion of the metal sheet that is bent to have a bend radius of about 3-9 mm, where the edge portions attach in abutting and continuous contact with the common center wall to form crevices between the adjacent tubular sections along the first and second faces. A weld is formed in each of the crevices to define crevice ribs in general alignment with and at each of the opposing first and second ends of the common center wall that are configured to improve bending strength and torsional strength of the reinforcement beam.

Abstract: A brazed heat exchanger, having a block consisting of flat tubes and fins, having header tubes arranged at opposite ends of the flat tubes and having an additional tube, which is connected to one of the header tubes. To reduce brazing defects, provision is made for at least a significant part of an outer surface of the additional tube and/or of the header tubes to be of enlarged design.

Abstract: A reinforcement beam is roll formed from a metal sheet for use in a vehicle bumper system. The reinforcement beam includes adjacent tubes having a common center wall and lateral portions extending from opposing sides of the common center wall that are roll formed simultaneously in the same rotational direction to enclose interior volumes of the adjacent tubes and to define top and bottom walls and front and rear wall of the reinforcement beam. The front walls of the adjacent tubes each include a channel rib depressed into the interior volume of the respective adjacent tube longitudinally along the reinforcement beam for stiffening the respective front wall. A weld is formed separately in each of the seams between the front walls and between the rear walls, thereby defining a crevice rib between the channel ribs to improve the bending strength and torsional strength of the reinforcement beam.

Abstract: The formation of a resin layer, a metal layer and an insulating resin layer on an outer surface of a corrugated metal pipe for flowing a fluid provides a flexible pipe, whose corrugated metal pipe does not suffer from having apertures even with spark discharge by induced lightning.

Abstract: [Problem] A method for manufacturing a bent hollow pipe is provided, in which even when a three-dimensionally bent pipe is formed, a gap, an uneven thickness, and the like would not occur at contact portions at the ends of both of the flange portions when press work is finished, and thus a pipe having the high quality contact portions can be formed. [Solution] In a method for manufacturing a bent hollow pipe, a material W, which is to be processed and which is a flat plate extending a first plane formed by a first direction and a second direction perpendicular to the first direction, is pressed in a stepwise manner using a plurality of forming dies from a third direction perpendicular to the first plane, so that two sides of a second plane formed by the second direction and the third direction of the material W are brought into contact with each other, and the bent hollow pipe is made to be bent and extend in a three dimensional manner that is bent in the first plane and in the second plane.

Abstract: A UOE steel pipe used to form a structure by performing butt circumferential welding and having an outside diameter shape in a waveform in a longitudinal direction is shaped to have no local minimum of the outside diameter shape in the waveform within a predetermined length from both longitudinal end portions.

Abstract: A method for manufacturing a closed structure part has a closed section using a blank made from a metal plate by pressing the blank using a press forming die and fixing a pair of joint ends of the blank to each other, the method including a pre-forming step of processing the blank into an interim part having a closed section corresponding to the closed structure part, a closing step of, after the pre-forming step is completed, moving the joint ends of the interim part toward each other and urging, against one of the joint ends, a concave flange processing portion formed on one of a pair of press forming surfaces of the press forming die at the edge end adjacent to the other press forming surface, and a press joining step of, after the closing step is completed, further moving the press forming die in a pressing direction, bending the one of the joint ends using a pressing force applied from the flange processing portion so that the joint end overlaps the outer surface of the other join end and a latch flange

Abstract: A method of manufacturing bearing seal for use in a roller bearing is provided. A steel coil of a preselected width is fed into a ring rolling machine to form a closed coil ring. The closed coil ring is then welded along the butted joint. The welded closed coil ring is then fed to a series of pre-forming machines wherein the desired profiles of the final bearing seal are formed.

Abstract: In a method of making a tube, a sheet metal blank is placed in a U-shaped cavity of a lower mold of a shaping tool, and pressed into the cavity by a ram to shape the blank into a U-shaped configuration. In a next process step, the U-shaped blank is formed between an upper mold and a lower mold of a molding press into a tubular configuration. The upper and lower molds of the molding press with accommodated tubular profile are then clamped together and the clamped upper and lower molds are then removed from the molding press. Subsequently, the confronting longitudinal edges of the tubular profile are welded together via an opening that provides access to the longitudinal edges. After separation of the upper mold from the lower mold, another shaping cycle may begin.

Abstract: In an apparatus and method for manufacturing an automotive beam for use as a beam in structural components of automobiles, the beam is provided with significant improvements in terms of torsional rigidity and yield strength. The beam improves the overall safety of passengers and maintains the simplicity of the manufacturing process. The apparatus (1) for manufacturing roll formed profile beams comprises a plurality of material dispensers (2,6), a first set of rollers (5), a second set of rollers (11), a first welding station (10) mounted between the two sets of rollers (5, 11) and a second welding station (12) at the outlet of the second set of rollers (11). The method of manufacturing roll formed profile beams comprises the steps of roll forming a first profile element followed by roll forming a second profile element enclosing the first profile element and forming a closed profile beam having an internal support structure.

Abstract: A vehicle door beam of relatively small profile and high strength. The door beam is fabricated from a web and includes a beam portion and brackets extending from opposite ends of the beam portion. The beam portion includes two lateral portions of the web rolled inwardly into closed configurations, and the two lateral edges of the lateral portions are welded to the beam portion. In an alternative embodiment, a second web is included in the beam portion and is part of both of the closed configurations.

Abstract: The high yield ratio problem intrinsic in high-strength steel pipes is solved and a method of producing a steel pipe, while securing the pipe roundness is provided. A steel pipe produced from a steel plate by forming and welding is subjected to 0.3 to 1.2% of expansion and then to 0.1 to 1.0% of reduction. The steel pipe produced by this method has a structure in which martensite and/or bainite accounts for more than 80% as expressed in terms of area percentage, and has a yield strength of not lower than 551 MPa and a yield ratio of not higher than 93%. The pipe reduction is desirably carried out at a lower work ratio as compared with the pipe expansion.

Abstract: A method for forming a cylindrical body utilizing a continuous weld is provided. The method includes feeding a source material including a first edge and a second edge from a coil and offsetting at least one of the first edge and the second edge. The method further includes spiraling the material to form a cylinder, welding the first edge and the second edge together forming a continuous weld, and cutting the cylinder to a selected length. To fabricate a jacket, a longitudinal cut is made in the cylindrical body, at least one cutout is cut, and the continuous weld is an outer fillet weld.

Abstract: A bumper beam for a vehicle includes a hat beam (10) with a cover (14). The hat beam has a crown (11) and side flanges (12, 13), and the cover (14) is fastened to the side flanges. The crown is fastened to the vehicle body. The cover (14) extends past one of the side flanges (12, 13) and is stiffened by being transversely corrugated.

Abstract: In a method of making finned tubes as components of air-cooled systems or condensers, a sheet metal strip of aluminum is first shaped into a waved finned structure with plural fins in parallel relationship and arched ends for connecting the fins, thereby defining crests on opposite ends of the finned structure. A fluxing agent of cesium-aluminum tetrafluoride is applied in lines onto the crests on at least one of the ends of the finned structure. The finned structure is then placed upon a broad side of a flat steel tube coated with a zinc/aluminum alloy. The finned structure and the flat tube are subsequently joined in a brazing furnace in the presence of an inert gas at a temperature between 370° C. and 470° C. to produce a unitary structure which is then allowed to cool down at room temperature.

Abstract: In a method of making a cross member for a twist-beam axle of a motor vehicle, a band-shaped metal blank is shaped in a profiling unit in a continuous operation to a V-shaped or U-shaped double-walled hollow section having an outer wall and an inner wall, such that the outer wall of the hollow section extends, at least in an apex area thereof, at a distance to the inner wall of the hollow section, and that confronting longitudinal edges of the hollow section extend in the apex area of the outer wall. The confronting longitudinal edges of the hollow section are then joined by a longitudinal weld seam which is then smoothed. Subsequently the welded hollow section is cut to size to form a cross member.

Abstract: A method for forming a cylindrical body utilizing a continuous weld is provided. The method includes feeding a source material including a first edge and a second edge from a coil and offsetting at least one of the first edge and the second edge. The method further includes spiraling the material to form a cylinder, welding the first edge and the second edge together forming a continuous weld, and cutting the cylinder to a selected length. To fabricate a jacket, a longitudinal cut is made in the cylindrical body, at least one cutout is cut, and the continuous weld is an outer fillet weld.

Abstract: A structural material includes a plurality of discrete, interwoven wires disposed between and fastened to two solid face sheets. Each of the plurality of wires further includes at least two points of contact with each of the two face sheets. Methods for fabricating the aforementioned structural material include an automated methodology for fabricating a relatively inexpensive truss core sandwich panel.

Abstract: An apparatus and method of manufacturing a wellscreen for subterranean use in oil, gas, and water wells, incorporating numerous automated processes, whereby layers of mesh are continuously sintered to a perforated strip, formed into a tube, placed over a perforated base pipe, and sealed with end rings.

Abstract: Triboelectric sensors which generate electrical signals in response to mechanical disturbances creating relative motion of conducting and dielectric components of the sensor are fabricated from thin metal foil which is plastic-coated on one side and which can be formed into elongated, cable-like sensors having a variety of other shapes and sizes. The foil encloses one or more wire-like inner electrical conductors which, may be sealed within the envelope formed by the outer foil by heat-sealing the plastic-coated foil. A technique similar to welding may be used in which electrodes are placed in contact with opposing faces of the metal foil and an electrical current is passed though the foil. Local heating of the foil and of the plastic coating near the point of contact of one or both electrodes can cause the plastic to melt and the opposing plastic faces to bond together.

Abstract: Broadly, the present invention is directed to a method for making a metal tag bearing visible indicia thereon and which can be welded onto a workpiece. Such inventive method commences by providing a metal sheet having a top face, a bottom face, and a pair of ends. The top face bears a painted zone upon which is imprinted with visible indicia. At least one of the ends of the bottom face has exposed bare metal. Such bare metal end is folded so as to reveal the bottom face bare metal adjacent to the imprinted painted zone. The thickness of the folded ends is effective for the metal tag to be welded onto a metal workpiece at such folded tag end. Another aspect of the present invention is a metal tag bearing indicia thereon and which can be welded onto a metal workpiece. The tag includes a metal sheet having a top face, a bottom face, and a pair of ends. The top face bears a painted zone upon that is imprinted with visible indicia.

Abstract: Disclosed is an apparatus and method for making an automotive bumper beam by a single roll forming. The apparatus of the present invention comprises an uncoiler; a straightener; a brake press; a first group of roll formers; a second group of roll formers; a final sweep roll former; adjuster; welding member; and cutting member. The method of the present invention is comprising of a step of preparing the steel sheet; a step for forming the tubular cross-sectional shape on the steel sheet; a step for forming a sweep on the steel sheet; a step for adjusting the tubular cross-sectional shape of the steel sheet; a step for welding two flanges to each other at their terminal ends; and a step for cutting the steel sheet to the predetermined length.

Abstract: An apparatus for forming an end bumper for vehicles constructed from a single sheet of high-tensile strength steel roll-formed to provide two side-by-side tubular sections. Each section has a front wall, an outer side wall, a rear wall, and an inner side wall, the inner side walls being spaced one from the other and connected together by a web roll-formed integrally with the inner side walls. The front walls each have extended ends overlapping and abutting the web. The extreme ends of the front walls also form an abutting juncture which is welded together and also welded to the web. The bumper has a sweep formed by a sweep-forming mechanism having curvilinear an external guide mechanism and internal mandrels conforming to the outer configuration and inner configuration of the bumper so as to provide a passageway therebetween for receiving the bumper. The bumper is passed through the passageway while the roll-forming of the bumper takes place upstream of the mandrels.

Abstract: A method of producing an elongated member having a main body portion and terminal portions extending form ends thereof includes bending an elongated strip between circumferential faces of first forming rolls and second forming rolls having parallel central rotational axes. The circumferential faces of the first forming rolls include annular main body portion bending sections that form the main body portion in the strip and adjacent transition portion bending sections that form adjacent transition portions in the strip, thereby forming an intermediate stage elongated member. The transition portions have a cross-section that changes continuously from the annular cross-section of the main body portion to a different cross-section of the terminal portions.

Abstract: An end bumper for vehicles constructed from a single sheet of high-tensile strength steel roll-formed to provide two side-by-side tubular sections. Each section has a front wall, an outer side wall, a rear wall, and an inner side wall, the inner side walls being spaced one from the other and connected together by a web roll-formed integrally with the inner side walls. The front walls each have extended ends overlapping and abutting the web. The extreme ends of the front walls also form an abutting juncture which is welded together and also welded to the web. The bumper has a sweep formed by a sweep-forming mechanism having curvilinear external and internal mandrels conforming to the inner configuration and outer configuration of the bumper so as to provide a passageway therebetween for receiving the bumper. The bumper is passed through the passageway while the roll-forming of the bumper takes place upstream of the mandrels.

Abstract: There is provided a method for the manufacture of a welded tube having an enhanced inner wall. A fin insert shapes the edges of a metallic strip prior to welding and minimizes the formation of a weld bead inside the tube. The portion of the edge of the metallic strip adjacent the outer surface of the tube is formed to a first angle, while that portion of the edge adjacent an inner wall of the tube is formed to a second, lesser angle.

Abstract: A mechanism and method for counteracting and removing the twist of a rolled metal strip being formed into a tube by a tube forming machine. The mechanism has a frame rotatably mounted to the tube forming machine between the forming rolls and the seam guide. A pair of edge rolls are attached to the frame and are engageable with the opposing longitudinal edges of the rolled metal strip. Backing rolls, also attached to the frame, inhibit the transverse displacement of the rolled metal strip by the engagement of the edge rolls with the longitudinal edges of the metal strip. An adjustment screw rotates the frame relative to the tube forming machine about a longitudinal axis to align the longitudinal edges of the rolled metal strip with a seam guide prior to welding the longitudinal edges to each other.

Abstract: A structural member which comprises a pair of hollow end sections and an intermediate web characterized in that each hollow end section is welded to the intermediate web so as to form two weld lines or joins extending along the structural member. Suitably the intermediate web is predominantly planar and the structural member is formed from a unitary sheet of metal having opposed edges whereby a respective edge is located adjacent the intermediate web and is welded thereto form the weld lines or weld joins.

Abstract: A drum brake shoe is provided by fine blanking the brake shoe web (50) so that the web (50) has radially extending weld projections (60) at a circumferential edge (52), with a radial recess (62) disposed on each side of a weld projection (60). As a brake shoe rim (40) is fed through a welding and forming mechanism (65), a flat surface (41) of the rim (40) engages a radially extending weld projection (60) and a weld is effected. Welding wheels (90, 100) of the mechanism (65) rotate to bend the rim (40) and engage the rim (40) with the next weld projection as a weld is effected between the rim (40) and web (50). The manufacturing method will provide a more consistent welding process that will result in a higher percentage of quality welds and less scrappage.

Abstract: A bumper bar for vehicles formed from rolled sheet steel having a closed tubular profile designed to have a high impact resistance, high strength-to-weight ratio, and a low cost of manufacture. The bar is preferably swept along its longitudinal axis to create a curvature consistent with modern automotive design.

Abstract: A bumper bar for vehicles formed from rolled sheet steel having a closed tubular profile designed to have a high impact resistance, high strength-to-weight ratio, and a low cost of manufacture. The bar is preferably swept along its longitudinal axis to create a curvature consistent with modern automotive designs.

Abstract: Conventional apparatus for forming pressure vessels from tubing involves a separate step of the forming of the tubing into coils and then separately welding the coils together. The conventional method has proven to be costly because of the type of apparatus required as well as time consuming and frequently producing a poor quality product when the welding is done independent of coiling step. The subject apparatus overcomes these problems by providing a collapsible mandrel to which tubing is wrapped to form coils for a pressure vessel and simultaneously welding the coils together in one step. The coils are guided on the mandrel by a carriage means which is controlled by a hydraulic system to maintain the coils into intimate contact with each other as they are being welded together. A welding torch, also carried by the carriage, is guided by the forming of the coils rather than some guide means to guide the welder independently of this operation.

Abstract: In a method and apparatus of forming a flat metal strip into a tube having generally flat side walls connected by bight portions along their opposite longitudinal edge portions comprising the steps of directing the strip between a pair of form rolls to bend the opposite longitudinal edge portions of the strip into similar generally upwardly curved edge portions; then directing the strip between a second set of rolls which engage the upwardly curved edge portions to center the strip laterally relative to the rolls and bend the strip along its longitudinal center line to form an upwardly rounded bend therealong while maintaining the portions of the strip on the opposite sides of the center bend relatively flat whereby to impart to the strip a V-shaped cross section having a central apex and oppositely upwardly inclined flat legs, each terminating in a laterally inwardly curved edge; directing the V-shaped strip between one or more additional sets of form rolls to increase the circumferential extend of said apex

Abstract: A welded tapered tube is made by deforming a flat, elongated trapezoidal sheet of metal into an elongated, U-shaped trough in a wagon open at its top and having a U-shaped trough for a bottom. The wagon moves along a track to carry the U-shaped sheet past a series of fin rolls, which deform the U-shaped sheet into an oval-shaped, tapered tube with a seam running the length of the tube. The wagon and tube thereafter move past a welding station where the seam is forged and welded together to form an elongated, tapered tube with an oval-shaped cross section, which may be squeezed between two elongated and semicircular die cavities to form a tapered tube of circular cross section.

Abstract: A method and apparatus for forming thin-wall tubing in a funnel die or with a series of sets of forming rollers. The tubing is then welded by a method and apparatus which includes simultaneous guiding of the both the inner and outer peripheries of the tubing during the welding operation by a mandrel and a sleeve, respectively, so that lack of rigidity of the tubing is not a limitation. The edges of the tubing are not clamped, but are allowed to "float" during welding. The resulting tubing is highly uniform. A wide range of tubing materials can be welded and thin-wall tubing of nearly any desired length or wall thickness can be produced.

Abstract: An apparatus for guiding can bodies in a laser welding machine is described. The apparatus comprises a water-cooled holding-down shoe (22) with an integrated holding-down roller (24), gas supply (64) and suction extraction (68), the holding-down roller (24) being disposed in front of the theoretical point of intersection of the two edges of the body to be butt-welded and being adjustable in height, with the holding-down shoe (22), to the thickness of the sheet metal. Adjacent to the holding-down shoe (22) is a holding-up shoe (26) and adjacent to the holding-down roller (24) is a holding-up roller (28). Provided below the holding-up shoe (26) is a horizontally and vertically adjustable supporting roller (30) which supports the can bodies at their underside during the welding operation and during passage through the welding plane (10).

Abstract: An apparatus for continuous production of seam-welded steel tubing is proposed. The apparatus includes a series of shaping rolls for shaping a strip taken out from a strip coil into a tubular intermediate product, the roll series including a finpass roll group. The tubular product is subjected to seam welding under the action of a seam welder. Before arrival at the welder, a substantial main part of the preformed tubing with exception of opposing edge zones thereof is subjected to heating by a heater compensate for excess compressive stresses induced in the edge zones, while these zones are subjected to cooling by a cooler for avoiding otherwise formation of disadvantageous edge wavings which would otherwise occur.

Abstract: In the manufacture of welded pipes, edge buckling or waving of the strip is prevented by heating. In one method, during the process for bending the strip into a tubular form, the edges of the strip are heated so that tensile stress exerted thereon is reduced to a minimum and, thereafter, before the edges are abutted against each other, the strip is wholly heated so that the compressive stress exerted on the edges is reduced to a minimum. According to another mode, during the process for bending the strip gradually into a tubular form or during the process in which the edges of the strip are held in abutment against each other, the strip except its portions at the edges is substantially or partially heated so that the strip except its portions at the edges is subjected to compressive stress while the portions of the edges are subjected to tensile stress, and under these conditions the edges are welded together.

Abstract: In a method for roll forming a flat metal strip through a roll forming machine into a round tubular product while the metal strip is being lengthwise fed therethrough, an improved method wherein regions of a specified width extending inward from the edges of said strip are imparted with substantially zero curvature. The tube forming method prevents decrease in the wall thicknesses at the edges when used in the manufacture of a thick walled electric welded pipe, and prevents the occurrence of edge buckling and springback when used in the manufacture of thick walled pipe so that in either case a proper and satisfactory butt junction for subsequent welding can be obtained.

Abstract: A process for producing large-sized square steel pipe includes the steps of continuously paying off steel plate from a roll of the same, removing strain from the plate while conveying the plate, and cutting the plate to predetermined lengths. The lengths of plate are successively bent into a shape resembling a rectangular or square pipe having corner portions with angles slightly larger the 90.degree.. The successive plates are tack-welded and opposed outer rollers are pressed against the outer sides of the plate while the plate is conveyed longitudinally thereof. The opposed edges of the plate are thereafter welded together by high frequency welding.

Abstract: An apparatus for positioning and guiding the opposed edges of sheet metal so that the edges thereof are progressively moved into substantially intimate relationship with one another so that such edges may be subsequently welded to form a seam. The apparatus includes three replaceable guide elements that cooperatively form opposed and relatively converging guide channels which progressively direct the sheet metal edges into intimate relationship and maintain such relationship as the sheet metal is introduced into a seam welding station.

Abstract: A method and apparatus for manufacturing metal pipe. The edges of a metal plate are bent up slightly, and the thus bent plate is then bent into a U-shape cross-section blank. The U-shape blank is finish-formed into an O-shaped blank with the longitudinal edges opposed to each other in a position for welding by placing one end of the U-shaped blank into at least one two-part die the parts of which are movable toward and away from each other.

Abstract: A machine for fabricating a helicoidal tube from a longitudinal flat and bendable strip includes a frame, and tube-forming means disposed on the frame for receiving the longitudinal flat strip. The strip is then formed into a tube which has a seam. Helicoid-forming means are disposed on the frame for receiving the tube and for the forming thereof into a helicoid.