Abstract: A method of making a medical device includes compressing a prosthesis, e.g., a therapeutic agent-carrying stent or stent-graft, to a catheter without contacting an outer surface of the prosthesis, e.g., by electromagnetically compressing the prosthesis.

Abstract: Apparatus and methods are disclosed for applying electromagnetic force (EMF) to flanging and hemming metal panels to form a hemmed panel assembly. First and second apparatus and method steps use a translating EMF coil to flange a sheet and to finish a hem by progressive non-planar bending. An alternate embodiment uses EMF hemming for difficult-to-hem portions of a flange and optionally precedes this with conventional hemming of straight hem portions.

Abstract: Method for producing a coated medical support device capable of insertion into the body, the method including the procedures of applying a coating to a section of a work-piece, positioning the work-piece in the vicinity of an electromagnetic field generator, and substantially proximate a forming mandrel, inducing electromagnetic forces in the work-piece which accelerate the work-piece toward the forming mandrel, and forming the work-piece to a medical support device, by changing the original physical configuration of the work-piece to a second physical configuration, the forming mandrel having a mandrel physical configuration, the second physical configuration being influenced by the mandrel physical configuration.

Abstract: Electromagnetic (EMF) trimming, flanging and hemming steps are performed at a single workstation in a combined fixture designed to form a hemmed panel assembly, such as a vehicle closure panel. Two or more formed sheets, outer and inner panels, are positioned together for hemming. The panels are clamped and EMF coils are activated to provide EMF force to retain the panels and trim off excess addendum material from the outer panel. The coils are then activated to bend the trimmed edge upward against a flanging member and form a 90 degree flange. Flanging and trimming members are retracted and a coil member positions EMF hemming coils opposite the flange. The hemming coils are then activated and apply EMF force to bend the flange of the outer panel to a 180 degree angle, overlaying the edge of the inner panel and forming a panel assembly having a hemmed edge. Optionally, if needed, the flanging member is then lowered against the flange to assure flatness of the hem.

Abstract: An apparatus (30) and method for forming of a vehicle's driveshaft (32) is provided which makes use of a PMF process. The coil device used in the PMF apparatus is assembled around the shaft from two or more coil sections (40, 41, 43; 42, 44, 45) firmly attached to one another, and which may be disassembled from one another to allow to remove the formed driveshaft (32).

Abstract: Methods are provided for forming a plurality of permanent magnets with two different north-south magnetic pole alignments for use in microelectromechanical (MEM) devices. These methods are based on initially magnetizing the permanent magnets all in the same direction, and then utilizing a combination of heating and a magnetic field to switch the polarity of a portion of the permanent magnets while not switching the remaining permanent magnets. The permanent magnets, in some instances, can all have the same rare-earth composition (e.g. NdFeB) or can be formed of two different rare-earth materials (e.g. NdFeB and SmCo). The methods can be used to form a plurality of permanent magnets side-by-side on or within a substrate with an alternating polarity, or to form a two-dimensional array of permanent magnets in which the polarity of every other row of the array is alternated.

Abstract: A method for manufacturing a combined driveshaft tube and yoke assembly includes the initial step of orienting a first component having a first wall thickness and a second component having a second wall thickness to define an overlap region. The first and second components may have the same or different wall thicknesses, may be formed from the same or different materials, and may have the same or different lengths. Portions of the first and second components are deformed to provide the overlap region with a third wall thickness that is the sum of the first wall thickness and the second wall thickness. Lastly, a pair of yoke arms having respective openings therethrough is formed in the overlap region to provide a combined driveshaft tube and yoke assembly. A pair of combined driveshaft tube and yoke assembly can also be manufactured in accordance with this method.

Abstract: A device for electromagnetic high energy pulse deformation of workpieces of an electrically conductive material has a deformation tool including a coil carrier and at least two partial coils arranged on the coil carrier, at least one surge current generator to which the partial coils are connected so that magnetic fields of the partial coils superpose to form a resulting magnetic field which acts on the workpiece, the partial coils being formed as spiral coils which are formed identically with respect to inductivity, electrical resistance, winding number and forming, and each of the partial coils extending on the coil carrier from an inner starting point in an identical form and with a corresponding identical distance to a neighboring one of the partial coils in a spiral-shaped manner outwardly; and a method of electromagnetic high energy pulse deformation is proposed as well.

Abstract: A pressure damper for use with a fluid conduit, such a fuel rail in a vehicular fuel delivery system, is manufactured by deforming a workpiece, such as by stamping, hydroforming, or magnetic pulse forming, to have an enlarged portion of predetermined size and reduced wall thickness. The predetermined size and reduced wall thickness of the enlarged portion correspond to a magnitude of fluid pressure at which the enlarged portion will flex or otherwise behave elastically, allowing the enlarged portion to function as a pressure damper. The workpiece can be secured to a fuel rail, such as by brazing, quick-connects, O-ring joints, welding, gluing, or magnetic pulse forming or welding techniques. Alternatively, the workpiece is embodied as the fuel rail itself, and the pressure damper is formed integrally with the fuel rail, thereby eliminating the need to secure a separate damper to a fuel rail.

Abstract: A pair of metallic components, such as a pair of metallic structural components for a vehicular body and frame assembly, are permanently joined using a magnetic pulse welding process. Initially, a first metallic component is provided having a first aperture that is formed through a first side and a second aperture having a hollow cylindrical flange portion that is formed through a second side. A second metallic component is provided having a surface that extends at an angle relative to the flange portion. The angled surface may be provided in the form of either an enlarged region or a reduced region on the second metallic component. The first and second metallic components are arranged such that the flange portion of the first metallic component overlaps the surface of the second metallic component.

Abstract: A scheme for electromagnetic formation of fuel cell plates is provided. In accordance with one embodiment of the present invention, a method of forming a flow field plate is provided where an electromagnetic actuator is arranged opposite a profiled surface of a die portion. The profiled surface of the die portion is configured to at least partially define a network of flow field plate flow passages. The electromagnetic actuator is configured to generate a magnetic field upon activation and a sheet of material is positioned between the electromagnetic actuator and the profiled die surface. The sheet of material is characterized by an electrical conductivity sufficient to yield a repulsive electromagnetic force between the actuator and the sheet upon activation of the actuator. The passages are formed by driving the electromagnetic actuator such that the repulsive force is of sufficient intensity to deform the sheet against the profiled die surface.

Abstract: A scheme for deforming a sheet of material is provided. In accordance with one embodiment of the present invention, an apparatus for deforming a sheet of material is provided. The apparatus comprises a die portion, an electromagnetic actuator, and a conductive frame. The die portion defines a profiled surface. The electromagnetic actuator is arranged opposite the profiled surface of the die portion. The conductive frame is configured to (i) secure the sheet of material in electrical contact with the conductive frame in a position between the electromagnetic actuator and the profiled die surface, (ii) permit deformation of the sheet of material against the profiled die surface upon activation of the electromagnetic actuator, and (iii) define a return path for eddy currents induced in the sheet of material upon activation of the electromagnetic actuator.

Abstract: An electric traction motor for a vehicle including a housing, a wound stator field located in the housing, a rotor magnetically interacting with the wound stator field, high energy magnets configured in the rotor, and low energy magnets configured in the rotor.

Abstract: The performance of a magnetic pulse forming or welding process is monitored by positioning a deformation member relative to an inductor coil of the apparatus, then energizing the inductor coil to exert a force thereon. The deformation member can be a plastically deformable tube, and the amount of such plastic deformation that occurs when the inductor coil is energized can be measured to determine the magnitude of the force that is generated by the inductor coil. Alternatively, the deformation member can be an elastically deformable body, and the amount of such elastic deformation that occurs when the inductor coil is energized can be measured to determine the magnitude of the force that is generated by the inductor coil.

Abstract: A method for securing components of a vehicular driveshaft includes disposing a neck of an end fitting into the open end of a driveshaft tube. The end fitting is held with respect to the driveshaft tube so that an annular gap is formed between the neck and the driveshaft tube. An inductor is provided about the driveshaft tube adjacent the end receiving the neck. The inductor is energized to generate a magnetic field for collapsing the driveshaft tube about the neck at a high velocity so that the driveshaft tube and the end fitting are welded to each other.

Abstract: A method of forming a slip joint includes providing a forming mandrel having a plurality of axially extending external splines, placing an inner tube circumferentially about the mandrel, and applying radially inward pressure on the inner tube to deform the inner tube and cause it to conform to the shape of the mandrel. The deformation step forms splines on the outer surface of the inner tube. A circumferential seal is then applied around the inner tube, and an outer tube is placed around the inner tube and the seal. Radially inward pressure is applied on the outer tube to deform the outer tube and cause it to conform to the shape of the inner tube, and thereby forming splines on the inner surface of the outer tube. The splines on the outer surface of the inner tube and the splines on the inner surface of the outer tube are configured to cooperate together to form a slip joint.

Abstract: A conjoining apparatus using electromagnetic forming includes a field shaper for concentrating a magnetic field to a conjoining working object, a coil for generating and applying the magnetic field to the field shaper such that the field shaper can form a reactive force, and a charging circuit for supplying electricity to the coil. An auxiliary ring having higher conductivity than steel is disposed between the field shaper and the working object for generating an induced magnetic field.

Abstract: A method of forming a torque tube (64) is provided. The method includes forming a fitting (80) having an elongated tube conforming area (88). The conforming area (88) includes chamfer areas (82) having upper surfaces (90), lower surfaces (92), and chamfer surfaces (94) that transition between the upper surfaces (90) and the lower surfaces (92) and have chamfer angles (96) of approximately 20 relative to the lower surfaces (92). An elongated tube (86) is procured and an end portion (106) of the elongated tube (86) is formed onto the conforming area (88) to form a torque-transmitting coupling (84). The torque tube (64) is also provided and formed according to the above-stated method.

Abstract: A method for securing components of a vehicular driveshaft includes disposing a neck of an end fitting into the open end of a driveshaft tube. The end fitting is held with respect to the driveshaft tube so that an annular gap is formed between the neck and the driveshaft tube. An inductor is provided about the driveshaft tube adjacent the end receiving the neck. The inductor is energized to generate a magnetic field for collapsing the driveshaft tube about the neck at a high velocity so that the driveshaft tube and the end fitting are welded to each other.

Abstract: A system and method for expanding, joining or securing a plurality of tubes by electromagnetic expansion to a plurality of sheets in a tubular heat transfer system. The system and method involve the automatic sensing and positioning of a electromagnetic coil in operative relationship with at least a portion of a tube and an inner wall of a sheet and then energizing the electromagnetic coil to expand the portion of the tube to engage the inner wall of the sheet, thereby securing the tube thereto. A tubular heat transfer system tube expander and method are also shown.

Abstract: A method for joining vehicle components together to form a vehicle frame assembly where the components are formed from dissimilar materials such as metallic and non-metallic materials. A composite body mount bracket may be attached to a structural component of a vehicle body and frame assembly by providing a body mount bracket having an opening formed therethrough and by providing a first structural component formed from a metallic material also having an opening formed therethrough. The body mount bracket is then positioned adjacent the first structural component such that the respective openings are aligned with one another. A second structural component formed of a metallic material is then inserted through the aligned openings. Next, the second structural component is welded first structural component through a magnetic pulse welding technique, and lastly, the second structural component is pulse formed or deformed so as to mechanically clamp the body mount bracket thereto.

Abstract: A method of forming a structural member includes hydroforming the blank to form a hydroformed member and finishing the hydroformed member by positioning the wall of the hydroformed member between a die surface and an electromagnetic discharging element having a non-circular cross-section, and actuating the electromagnetic discharging element so that the metallic wall of the hydroformed member presses against the die surface.

Abstract: A metal plate is formed in a process comprising cutting, perforating or both, by forcing the plate, by means of an abrupt and intense force towards a mold having openings or boundaries defined by wall sections which extend essentially normal to the forming plane of the mold. Consequently, the plate is cut along the edges of the openings or boundaries. The force may be a pulsed magnetic force or may be a force generated as a result of the discharge of electric current through a fluid.

Abstract: A method for securing components of a vehicular driveshaft includes disposing a neck of an end fitting into the open end of a driveshaft tube. The end fitting is held with respect to the driveshaft tube so that an annular gap is formed between the neck and the driveshaft tube. An inductor is provided about the driveshaft tube adjacent the end receiving the neck. The inductor is energized to generate a magnetic field for collapsing the driveshaft tube about the neck at a high velocity so that the driveshaft tube and the end fitting are welded to each other.

Abstract: A method of securing a restrictor, having an open hollow cylindrical end shell, to a spirally wound tuning cable having an end disposed in the shell, wherein the shell is magnetically deformed radially inwardly to grip and conform to the outer surface of the tuning cable end. The restrictor may be of steel, brass or, most preferably, aluminum construction.

Abstract: A method of fabricating a rotor for an electric traction motor including the steps of forming cavities in the rotor, injecting magnetic material in a portion of the cavities, injecting nonmagnetic material in a portion of the cavities, and post-magnetizing the magnetic material.

Abstract: In one embodiment, a method for manufacturing a device comprises disposing a first end around a second end, disposing an induction coil around the first end, discharging a current through the induction coil, forming eddy currents on the surface of the first end, and magnetic impulse sizing the first end and the second end together. The first end disposed around the second end comprises a tube end disposed around an end of the device or the first end disposed around the second end comprises the device end disposed around the tube end.

Abstract: An electromagnetic forming apparatus for forming an essentially planar metal plate into a dish having a three-dimensional pattern, is provided. The apparatus comprises a mould having a forming surface with a contour corresponding to said three-dimensional pattern; a forming coil device; and an electric discharge circuitry for discharging a short and intense electric current pulse through the forming coil device to yield a pulsed magnetic forming (PMF) force for deforming said plate.

Abstract: A load bearing structural joint that is fabricated using an electromagnetic process, features a tube that is joined to a fitting of another component. Lightweight materials and thicknesses can be used, because the welding is performed without the adverse effects of annealing or heat. The fabricated structure has an improved strength to weight ratio, and prolonged fatigue life.

Abstract: A method for securing components of a vehicular driveshaft includes disposing a neck of an end fitting into the open end of a driveshaft tube. The end fitting is held with respect to the driveshaft tube so that an annular gap is formed between the neck and the driveshaft tube. An inductor is provided about the driveshaft tube adjacent the end receiving the neck. The inductor is energized to generate a magnetic field for collapsing the driveshaft tube about the neck at a high velocity so that the driveshaft tube and the end fitting are welded to each other.

Abstract: In accordance with the invention, the vacuum pump cooling system includes tubes expanded along their entire length in bores through the vacuum pump body. The tubes can be made of stainless steel, and inserted into a vacuum pump body made of cast iron. This prevents the risk of corrosion of the vacuum pump body by a cooling liquid passing through the tubes to cool the vacuum pump body.

Abstract: A method of forming a heat exchanger stack from a plurality of plates, wherein the plurality of plates includes at least first and second nestable plates formed of an electrically conductive material. Each plate has a generally flat central portion and at least a pair of edge portions generally non-coplanar relative to the respective central portions of the plates. Each plate has a plurality of protrusions which is formed so that, when the plates are in a stacked, nested position, the respective pluralities of protrusions of the first and second plates engage each other, such that the respective central portions of the plates are spaced apart, thereby to define therebetween a space through which a heat exchanging medium may be passed.

Abstract: A method of manufacturing a sleeve mechanism without the use of machines by using a hydroforming process. The method includes the steps of providing an inner sleeve, an intermediate sleeve, and an outer sleeve concentrically within one another. The concentric sleeves are then expanded by using a hydroforming process such that an external thread is formed on the inner sleeve and an internal thread is formed on the outer sleeve. After the hydroforming process, the intermediate sleeve is removed by using any desired manner, such as melting or chemical dissolution. The relatively small space remaining between the inner and outer sleeves allow them to freely rotate about each other to ensure smooth operation of the screw and sleeve mechanism. Alternatively, the inner and outer sleeves may be hydroformed in separate operations.

Abstract: A method of manufacturing a collapsible driveshaft assembly includes the steps of disposing an end of a first tube within a forming die having a non-circular cross sectional shape, expanding the end of the first tube into conformance with the die cavity, inserting an end of a second tube is inserted within the deformed end of the first tube, and expanding the end of the second tube into conformance with the end of the first tube. As a result of this expansion, outwardly extending regions and inwardly extending regions of the second tube extend into cooperation with outwardly extending regions and inwardly extending regions of the first tube so as to cause the first and second tubes to function as cooperating male and female splined members. As a result, a rotational driving connection therebetween to form the driveshaft. When a relatively large axial force is applied to the ends of the telescoping driveshaft, the second tube will move axially within the first tube, thereby collapsing and absorbing energy.

Abstract: A process for forming closed sections using electromagnetic force. A sheet metal stock is folded into a generally closed section having flanges. The folded section is placed in a die and the die is closed. An electromagnetic force is applied to the die to expand the sheet metal towards interior walls of the die, thereby forming the closed section to a predetermined shape. During expansion, the flanges are drawn inward toward the die. After removed from the die, excess flanges are trimmed from the section if needed, the sections welded closed.

Abstract: An apparatus is provided for constructing a segmented annular permanent magnet from a predetermined number of previously magnetized segments of predetermined shape and size comprising a rotateable carrousel, at least two of a plurality of removable ferromagnetic segments, an introducing means and a removing means.

Abstract: A method for fabricating an automotive spaceframe using Electromagnetic Pulse Forming (EMF) or Magnetic Pulse Welding (MPW) techniques. The spaceframe can be either an all aluminum structure or a combination of dissimilar materials, such as aluminum and steel. The welding or forming methods can include the use of split coils or split inductors that allow for ease of access to the joints to be bonded in the spaceframe.