Abstract: A pair of self-aligning non-pinching hydroforming dies have fingers and slots which are operable during closure of the dies on a tubular part to effect precise alignment of the dies as they are pressed together to form a hydroforming cavity about the part so that the part is not pinched between mating surfaces of the dies during their closure on the part. The fingers are further capable of mechanically straightening and/or bending the part, if need be, to prevent pinching of the part during die closure. The fingers are also capable of mechanically forming a round tubular part to a non-round cross-section region of the die cavity as the dies close to help form the part as well as prevent pinching of this section. With all such mechanical forming operations by the action of the fingers on the part performed prior to the hydroforming of the part in the die cavity.

Abstract: The present invention provides a method and apparatus for forming a sheet of ductile material by superplastic forming. Excessive wrinkling is prevented in the present invention by providing a method and apparatus which controls the amount of material flow during the forming process.

Abstract: A device and method for joining fitting parts provided with a passage opening on hollow profiles through partial expansion of the hollow profiles at the location of the fitting parts is provided. The fitting parts are slid on with the passage openings and are held in position by means of fluid high internal pressure expansion of the hollow profile. The device includes an expanding lance, which can be slid into the hollow profile and exhibits an axial borehole for the purpose of guiding the pressure fluid. The axial borehole is connected to a fluid high pressure generating system and exhibits a cross channel with an outlet for the pressure fluid in the direction of the hollow profile location to be expanded. The shell surface of the expanding lance exhibits sealing elements that are spaced apart and that define the outlet so as to seal axially on both sides against high pressure.

Abstract: A process and a device produces an assembly linkage on a hollow profile which is shaped for the installation of the assembly part by internal high-pressure remodeling. In order to achieve the shaping of an assembly linkage in a component space-saving, for a subsequent assembly correctly positioned, and with regard to its contour exactly fitted to the assembly part, in simple manner and even with high degrees of remodeling in a secure process, the hollow profile, under internal pressure, which is smaller than the remodeling pressure, is indented at the place of the to-be-produced assembly linkage by a die and by forming a rough contour. Afterward, while the die remains in this indenting position, a fluid high pressure is created in the hollow profile. Thereby, the hollow profile sides surrounding the die are molded to the external contour of the die, and that after releasing the fluid high pressure and the subsequent removal of the die, the finished trough-shaped assembly linkage is released.

Abstract: A device for forming a hollow profile formed as a multi-chamber profile by an internal high pressure generated by a fluid pressure medium within the hollow profile containing a sealing die engaging in the profile chamber with a carrier part and a collar arranged on the carrier part sealing the face side of the profile chamber. The die also has a passage opening as a pressure medium supply and/or extraction channel. The collar is a resilient rubber die part arranged on the face of the carrier part facing the profile chamber and on the free face of the collar is provided a preload plate which is anchored by way of the fixing member penetrating the collar in the carrier part lying on the collar so that the collar is squeeze-clamped between the preload plate and the carrier part.

Abstract: First and second hollow bodies each having at least one opening are joined by first forming a fracture zone in a joint region of the first body and then juxtaposing the bodies in a closed cavity of an internal high-pressure shaping tool with the second body spaced from and open toward the fracture zone of the first body. The first body is then internally pressurized with a hydraulic medium until a burst pressure at the fracture zone is exceeded and the first body ruptures and is deformed outward at the fracture zone into engagement with the second body. The medium then flows through the ruptured fracture zone into the second body.

Abstract: A hydroformable frame element is formed from the combination of at least two elements. The at least two elements are designed with a partially overlapping region, with an annular space defined within the overlapping region. The annular space is filled with adhesive, which is then cured to bond the at least two elements together. The adhesive bond is designed to withstand the stresses caused by the hydroforming operation and to retain its strength so that the hydroformed article is then usable as a vehicular frame element.

Abstract: In the process for the monolithic molding of superplastic material, generation of wrinkles on the molded product can be prevented by avoiding local expansion generated in the no-bonding regions of both of three or more metal plates when the metal plates are monolithically molded by means of superplastic molding. The process is characterized in that auxiliary plates for molding are placed on both sides of the superposed plates through the no-bonding regions, these plates are set in the molding die, and a pressure lower than applied to the non-bonding regions is applied to spaces between inner wall of the molding die and the auxiliary plates to control movement of the top and bottom.

Abstract: The invention relates to method for producing a hollow body (26) from sheet metal, especially from aluminum or aluminum alloys. According to the inventive method, a substantially flat sheet metal blank (4) is provided. At least one wall intermediate element (8) which is produced as one piece with the sheet metal blank (4) is folded and/or bent into several substantially superimposed layers. Marginal areas (16, 18) of the sheet metal blank (4) are placed closely side by side, preferably they are placed on top of one another in such a manner that they overlap to some degree, and they are connected to one another. The sheet metal blank (4) and the folded wall intermediate element (8) are subjected to a hydraulic or pneumatic internal high pressure so that the folded wall intermediate element (8) is freely unfolded to form the hollow body (26).

Abstract: A method for manufacturing a driveshaft for use in a vehicle drive train system that is axially collapsible in the event of a collision to absorb energy. A workpiece, such as a hollow cylindrical tube, is deformed by hydroforming to provide an axial collapse initiation zone. The axial collapse initiation zone can be defined by a plurality of axially extending undulations or corrugations that are formed in a central portion of the tube. The axial collapse initiation zone is designed to accommodate the transmission of torque through the driveshaft without any deformation under normal operating conditions. However, if a relatively large axial force is applied to the front and rear end portions of the driveshaft, the axial collapse initiation zone is designed to allow relative axial movement to occur between the front and rear end portions of the driveshaft. Such collapsing functions to absorb energy during a collision, thereby providing additional safety to the occupants of the vehicle.

Abstract: A fluid formed node is provided to connect structure in an automotive vehicle. Another aspect of the present invention includes a method of forming a structural interconnection including the steps of placing a first member, having an internal cavity in a die pressurizing the internal cavity to form a node integral with and protruding from the first member, disposing the node within an aperture of a second member, and coupling the second member to the node.

Abstract: A hydraulic expansion mandrel for expanding tubes in a heat exchanger tube bundle into a tubesheet is formed from a non-metallic material, such a carbon fiber-reinforced material. The mandrel includes an elongated cylinder having a tip, a fluid supply end and a reduced diameter section. A pair of O-rings separates the reduced diameter section from the tip and fluid supply end of the elongated cylinder. An adjustment shim, located between a threaded collar and a locking stop collar, adjusts the length of the mandrel inserted into a tube.

Abstract: In the present invention, at least one tubular blank and at least one article such as a metal stamping, to be attached to a hydroformed part, are loaded into a die. The tube is hydroformed using typical methods. The article is positioned in the die such that, when the tube is hydroformed, the final hydroformed tube contacts the article at least at a point. Attachment means, such as a laser welder, are provided with access to the contact point between the article and the hydroformed tube so that a tack weld or other attachment can be made between the article and the hydroformed tube while still in the closed die. The hydroformed tube and attached article are then removed as a joint assembly from the die.

Abstract: In a process for the manufacture of a blade/vane of a turbomachine, the blade/vane is made of a metallic enveloping structure and a supporting structure made of composite material provided inside of the enveloping structure and suitably joined to the enveloping structure. A metal-felt weave is welded or soldered/brazed to the sheet making up the enveloping structure, whereupon this sheet-weave-assembly is shaped by hydroforming or an internal high-pressure forming process to provide the enveloping structure of the blade/vane. Finally, the composite material making up the supporting structure is introduced into the cavity of the enveloping structure.

Abstract: A sheet of aluminum is formed to a mold by applying gas pressure. Thermoplastic resin is heated and applied to the aluminum in a selected pattern through a nozzle. In one embodiment, the thermoplastic resin is applied to the aluminum sheet in a hexagonal pattern that transitions to a columnar pattern. In a further embodiment microballons or micro-spheres are added to the heated thermoplastic resin to reduce viscosity. A backing layer of aluminum sheet is formed to the patterned resin composite. Gas forming of the aluminum sheet results in aspect ratios of up to 0.6, and the sheet maintains a clean surface that directly bonds to the applied resin.

Abstract: A hydroformed tubular structure includes at least two hydroformed members connected at a joint. At least one of said members includes a flattened portion having opposite sides in engagement. One of the sides engages and is secured to a mating portion of another of the members and a hydroformed conjugate portion is formed in the one side adjacent the flattened portion and is secured in a recess of the other member. A hydroformed structural portion extends from the conjugate portion in a direction away from the flattened portion.

Abstract: A plurality of closing cylinder devices are provided between a bolster of a press machine and a bed containing a lower mold of a hydroforming device. An upper mold is attached to a slide of the press machine. The upper mold and lower mold come together to form a cavity having the shape of the exterior of the desired molded product. A closing block, being movable between a first position which is between the slide and a crown of the press machine, and a second position, which avoids the slide, permitting free movement of the slide from the crown to the lower mold. When a material to be hydroformed is place in the lower mold, the upper mold is lowered. The closing block is fit into its first position, thereby restricting movement of the slide in the vertical direction. A inner work pressure is provided by a fluid inside the material to be molded.

Abstract: A method of forming a tubular axle assembly is provided. The method includes providing a non-circular tubular member such as a rectangular tube having an end portion. The end portion is formed to provide a first generally circular end. A king pin boss is provided with a second generally circular end of approximate the same size as the first generally circular end. The two ends are friction welding together, and the tubular member are bent to a desired axle shape. In addition, a bulk head may be inserted into the tubular member prior to forming the end portion. The first circular end is preferably formed by a swaging or pointing process to reduce the cross-sectional area of the tubular member and form the circular end. The axle may then be processed by heat treating, quenching, and tempering the axle. Straightening of the axle may also be desirable.

Abstract: A method for manufacturing an air-gap-insulated exhaust pipe having a branch stub, as well as an exhaust pipe produced according to such a method and a tool for forming such an exhaust pipe. Two tubes are inserted into one another to form a double tube. The double tube is placed in a first internal high-pressure shaping tool, and exposed to internal high pressure fluid such that it expands to match the contours of the engraving of the first shaping tool, and a double-walled branch stub is blown out of the double tube. The partially formed double tube is then placed in a second internal high-pressure shaping tool, with the double tube being surrounded, between the two ends including the branch stub, circumferentially and throughout by a corresponding design of the engraving, by an expansion chamber.

Abstract: A method of operating a metal forming press in which in a rigid press frame a workpiece is preloaded against a tool by means of a hold-down force, with at least one ram tool applying a ram force in parallel with the hold-down force, and closing cylinder forces being applied opposite to the ram force and the hold-down force, and a water chamber die being formed in the tool, whereby water chamber die forces can act on the workpiece, characterized in that the disturbing force resulting from the application of the ram force is determined and compensated by a change in the closing cylinder forces.

Abstract: A method for forming a closed channel structural member having a central portion that is enlarged relative to the end portions thereof is disclosed. Initially, first and second tubes are formed in respective hydroforming dies to have desired shapes that are preferably characterized by a relatively large diameter first end portions and relatively small diameter second end portions. Each of the two tubes is then oriented such that the relatively large diameter first end portions are disposed adjacent to one another. Lastly, the relatively large diameter first end portions are joined together in any conventional manner, such as by butt welding, to form a unitary member characterized by a relatively large diameter central portion extending between a pair of relatively small diameter end portions. The unitary member can be used as a component, such as a side rail, of a vehicle body and frame assembly.

Abstract: A device for manufacturing a hollow body from two plates. The device includes an internal high pressure forming tool having an interior surface defining a mold chamber corresponding to a shape of the hollow body. The forming tool being arranged to receive two plates resting against each other. An expansion lance is insertable between the plates via an axial drive, and the expansion lance and the axial drive forming a pushing plunger. The expansion lance has a pinching section along a circumferential contour, and the plates to be pinched are arranged between the pinching section and the forming tool. The expansion lance includes a feed bore communicable with a high pressure fluid source. The expansion lance defines an axial stop to abut axial edges of the plates. The axial stop has a radial periphery which is smaller than that of the mold chamber.

Abstract: A method and device for connecting two components by way of high fluid pressure are provided, the components being pushed onto one another, and the two components then being pressed against one another by way of the high pressure. In order to interconnect components in a relatively simple and controlled manner without any limitation with regard to the minimum size of an inside diameter of the components and with regard to the design of the inner component, the outer component, the material of which has a yield point which is lower than that of the inner component, is plastically deformed by high-pressure action acting on the sliding assembly from outside, the inner component being elastically deformed. An assembly of the components is also provided.

Abstract: A method is disclosed for manufacturing a vehicle body and frame assembly including a pair of side rails, each of which is formed from a single closed channel structural member that extends the entire length of the vehicle body and frame assembly and is deformed into a desired shape by hydroforming. The first step in the process is to provide a length of stock material, preferably a tubular metallic workpiece, having a predetermined length. The tubular workpiece is then typically pre-bent by a conventional tube bending apparatus to have some or all of the bends in the side rails to be formed. The bends initially formed in the workpiece during this pre-bending step usually do not have the exact angles and shapes which result in the final product. Rather, this initial pre-bending operation is performed to facilitate the insertion of the workpiece within a die cavity defined by cooperating die sections of a hydroforming die.

Abstract: A fluid form that is used to produce deep-drawn articles (cf. 10) on any presses, and includes a ram (2), a hold-down plate (3) and a die (4), which can be filled, preferably, with water, wherein the sheet metal (10) to be deep-drawn is guided transversely between die and hold-down plate, should be improved in such a manner that no additional tools are required to trim the deep-drawn articles (cf. 10) and, optionally, for other operations. Hereby, the configuration of the respective fluid form as combination tool (1) is provided for the deep drawing operation and for further operations, such as trimming, wall profiling, notching, perforating or the like.

Abstract: A method of producing hollow front axles industrial vehicles including the steps of fluoforming a tubular blank to obtain an intermediate product having reduced-diameter ends, crushing the intermediate product to obtain a central portion of elongated section and bent intermediate portions, and finishing the axle by hydroforming.

Abstract: The present invention provides a hydroforming system and method eliminating the need for a solid steel die (or mold) set operated by a conventional high tonnage hydraulic press. The invention utilizes a fabricated or bar-stock die set integrated to a series of adjustably placed hydraulic cylinders to create a self-contained operating unit. The system can include a die set, a plurality of activation and clamping hydraulic cylinders, a computer control system and reinforcement and support structures. The die set can be a mounted lower die half and an adjacent movable upper die half, each constructed of individual pieces of plate or bar stock. The computer control system interprets incoming linear position data from all of the activation hydraulic cylinders and monitors and controls hydraulic fluid flow into and out of each cylinder. The system can also have a plurality of support pillars affixed to the lower die half.

Abstract: In the present invention, at least one tubular blank and at least one article such as a metal stamping, to be attached to a hydroformed part, are loaded into a die. The tube is hydroformed using typical methods. The article is positioned in the die such that, when. the tube is hydroformed, the final hydroformed tube contacts the article at least at a point. Attachment means, such as a laser welder, are provided with access to the contact point between the article and the hydroformed tube so that a tack weld or other attachment can be made between the article and the hydroformed tube while still in the closed die. The hydroformed tube and attached article are then removed as a joint assembly from the die.

Abstract: A device and method for joining fitting parts provided with a passage opening on hollow profiles through partial expansion of the hollow profiles at the location of the fitting parts is provided. The fitting parts are slid on with the passage openings and are held in position by-means of fluid high internal pressure expansion of the hollow profile. The device includes an expanding lance, which can be slid into the hollow profile and exhibits an axial borehole for the purpose of guiding the pressure fluid. The axial borehole is connected to a fluid high pressure generating system and exhibits a cross channel with an outlet for the pressure fluid in the direction of the hollow profile location to be expanded. The shell surface of the expanding lance exhibits sealing elements that are spaced apart and that define the outlet so as to seal axially on both sides against high pressure.

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 fuel rail for use in a fuel delivery system, such as for an engine in a vehicle, includes the initial hydroforming step to deform a central portion of a workpiece to have one or more outwardly extending node portions, followed by a subsequent hydroforming step to deform one or more end portions of the workpiece to have additional outwardly extending node portions. To do this, a pair of pressure feed pistons are disposed within the interior of the workpiece and have head portions that sealingly engage the inner surface of the workpiece so as to define a pressure chamber therein. Pressurized fluid is introduced into the pressure chamber so as to deform a portion thereof into conformance with the portion of the die cavity located within the pressure chamber. Then, the pressure feed pistons are moved to re-define the pressure chamber within the workpiece. Pressurized fluid is again introduced into the enlarged pressure chamber so as to deform other portions of the workpiece.

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 sheet hydroforming method is disclosed wherein two stacked metallic sheets are clamped between a pair of upper and lower dies 10, 11 and a fluid is introduced and pressurized between mating surfaces of the metallic sheets, causing the metallic sheets to bulge into a space defined by die cavities 10b and 11b. A thru-hole 11d for introducing the fluid is formed in one of the dies so as to lead to a holding surface of the die, while a pierced hole for introducing the fluid is formed in one of the metallic sheets in a portion of the one metallic sheet which portion is in contact with a holding surface 10a (10b) of one of the dies, the pierced hole being positioned with the thru-hole 11d, then the fluid is introduced in a pressurized state between mating surfaces of the metallic sheets from the thru-hole through the pierced hole, thereby causing the metallic sheets to bulge. According to this method, a pressurized fluid can be introduced between the mating surfaces of blanks easily without leakage of the fluid.

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 vehicle frame assembly includes a first vehicle frame component that is formed by deforming a closed channel structural member to have a relatively small end portion and a relatively large end portion. A member is provided having first and second ends. The relatively large end portion of the closed channel structural member is secured to the first end portion of the member to form the first vehicle frame component. A plurality of second vehicle frame components are provided. The first vehicle frame component and the plurality of second vehicle frame components are secured together to form the vehicle frame assembly.

Abstract: A process for forming an elongate structural element of desired shape being of large and small cross-sectional dimensions at spaced locations along its length, the process including the steps of: (i) selecting a first tube for forming a first selected length of the element having cross-sectional dimensions within a first range of relatively small cross-sectional dimensions within the hydro-forming-elongation ratio capabilities of the material from which the first tube is formed, said first tube being of a first constant cross-sectional dimension along its length, (ii) selecting a second tube for forming a second selected length of the element adjacent to the first length, the second length of the element having cross-sectional dimensions within a second range of relatively large cross-sectional dimensions within the hydro-forming elongation ratio capabilities of the material from which the second tube is formed, said second tube being of a second constant cross-sectional dimension along its length which is

Abstract: A method of making a gas tank includes hydroforming two halves and welding the halves together. Two types of welds are used in welding the two halves together, tack welds for holding the two halves together, and stitch welds to complete the welding of the two halves. Additional steps are taken prior to the finishing stitch welds. Reinforcement is added where necessary. Double tanks, for both gasoline and oil, are also fabricated by essentially the same method steps.

Abstract: In the present invention a tubular blank and an article such as a bushing to be assembled are loaded into a die. The tube is hydroformed using typical methods and, while the blank is still pressurized, a punch pierces a hole in the tube. The punch also has an article loaded onto it and, as the punch advances, the article is pushed into the tube through the pierced hole. The punch continues to advance such that it pierces a hole in the opposite side of the tube. The punch then retracts leaving the bushing in the tube. The article may alternately be inserted by means separate from the punch.

Abstract: A windshield wiper arrangement includes a mounting for a drive containing a wiper motor, a gear unit and a lever arm and two bearing brackets, spaced from the drive, containing wiper arm drive shafts each carrying an oscillating lever connected by a link rod to the lever arm. The mounting is an integral tubular structure shaped by high pressure forming of a tubular blank placed in a two-part mold having recesses extending essentially perpendicularly to the axis of the tubular part. Bushings for the drive shafts and a mount for the drive are forced into projections which are formed in the recesses when the tubular blank is shaped.

Abstract: A method and a device for producing leadthroughs on hollow profiles acted upon by a high fluidic pressure in an internal high-pressure forming tool. Dome-like secondary shaped elements are formed outwards in a radial direction from this hollow profile by the fluid pressurizing. The secondary shaped elements are then reverse drawn into the interior of the hollow profile by a punch while held at the prevailing internal high pressure, whereupon, to open the leadthrough, a punched slug is cut out of the base of the reverse-drawn secondary shaped element by the punch. To ensure the process reliability when producing the leadthrough even in the case of a hollow-profile material having low formability and to retain the strength of the hollow profile in the transition region to the leadthrough, in each case a secondary shaped element is formed out of the hollow profile at two opposite locations.

Abstract: A method for the production of a hollow body from aluminium sheet or alloyed aluminium sheet, especially a tank having at least one pipe mounted therein. Said method involves the following steps: preparing at least a cut flat sheet (10); placing at least one pipe (18) on the surfaces of the cut sheet to form inner surfaces of the hollow body being produced; folding and/or superimposing the cut sheet or sheets (10, 12) in such a way that a closed structure, with the exception of the inlet pipe and forming the hollow body by applying high pressure internally via the inlet pipe (18).

Abstract: A method and a device for producing leadthroughs on a hollow profile useing a high fluidic pressure in an internal high-pressure forming tool. Dome-like secondary shaped elements are formed outwards in a radial direction from this hollow profile by the fluidic pressurizing. The secondary shaped elements are then reverse drawn into the interior of the hollow profile by punches at the prevailing internal high pressure. A punched slug is cut out of the base of the reverse-drawn secondary shaped element by the punch. A bent-in margin of the secondary shaped element lying next to the cutout is then straightened by the punch in a displacing movement directed further inwards by being pressed against a hollow-profile wall.

Abstract: A method for producing a hollow body made of aluminum or an aluminum alloy comprises the following steps:

Abstract: The invention relates to a process for the manufacture of fiber-reinforced pressure vessels and the product produced therefrom. A vessel liner is wrapped with resin-impregnated fibers and cured according to conventional technology. The cured, fiber-wrapped liner is then subjected to a pre-treatment process comprising both elevated temperature and pressure over time. The elevation in temperature allows the resin to soften. The increased pressure imparts a tensile load in the fibers. The tensile load causes fibers to stretch and straighten in the resin. After cooling to typical operating temperatures, and when pressurized for duty, the now straightened fibers are capable of responding immediately to the tensile load and the burst strength of the vessel is increased as a result. The process can be combined with autofrettage in series or simultaneously to achieve even greater final strength.

Abstract: In a method and apparatus for fabricating a hollow body, preferably of sheet metal, such as for example automobile hoods and doors, at least two blanks are held sealingly together and the hollow body is then shaped by internal hydroforming.

Abstract: A method for manufacturing an engine cradle for use with a vehicular body and frame assembly includes the initial step of selecting desired materials for each of four hollow members that will be secured together to form the engine cradle. The selected materials can include metallic materials, such as steel, aluminum, magnesium, and non-metallic materials, such as fiber and other composites, or any combination thereof. The selected materials are formed into desired shapes using any known method, such as by hydroforming. Then, portions of the four members are disposed in a telescoping relationship with one another, such as by providing protrusions on some of the components and disposing the ends of the other components in a telescoping relationship with such protrusions. Lastly, the telescoping portions of the members are secured together using any securement method, including laser, MIG, or electromagnetic pulse welding techniques and adhesive bonding.

Abstract: In the present invention, at least one tubular blank and at least one article such as a metal stamping, to be attached to a hydroformed part, are loaded into a die. The tube is hydroformed using typical methods. The article is positioned in the die such that, when the tube is hydroformed, the final hydroformed tube contacts the article at least at a point. Attachment means, such as a laser welder, are provided with access to the contact point between the article and the hydroformed tube so that a tack weld or other attachment can be made between the article and the hydroformed tube while still in the closed die. The hydroformed tube and attached article are then removed as a joint assembly from the die.

Abstract: A process is for producing a circumferentially closed hollow profile, which is of frustoconical form in sections, from a sheet-bar blank. To produce hollow profiles of this type, the sheet bar is cut to size so that a blank with a rectangular section and a ring segment, the summit of which adjoins the center of one side of the rectangle, while its outer arc, which faces the rectangle, is of approximately the same length as the length of the side of the rectangle, is formed, sheet-bar material also being left on the blank outside the summit, between the ring segment and the side of the rectangle, this material joining the ring segment with the side of the rectangle integrally at all locations and also joining the corners of ring segment and rectangle which are closest together, so as to form a rounded edge contour. Then the side edges of the blank are bent into abutment with one another about the longitudinal center axis of the blank.

Abstract: A die button flush mounted in the cavity surface of a lower one of two hydroforming dies has a backup plunger received therein that forms a part of this surface when the plunger is in a hydroforming position. A slug ejector received in the lower die also forms a part of this surface and with a tubular part enclosed in the cavity formed by the dies, hydroforming fluid under pressure is supplied to the interior of the part and also to separately act on the plunger. The fluid pressure moves and holds the plunger in its hydroforming position while forming the part to the die cavity surface. The fluid pressure on the plunger is then exhausted allowing the fluid pressure in the part to stretch a portion of the part into the die button while also forcing the plunger to a position that limits this stretching to prevent piercing.

Abstract: The present invention relates to a method for manufacturing a hollow body made of metal whose cross sectional shape changes in longitudinal direction, a tubular slug being sealed at its end and being placed into a mold that corresponds to the desired shape and that is placed in a tool, said slug being then put under high pressure from the inside by means of a pressure means, whereas the two ends of the tube are pressed against each other in axial direction during the process of deformation, the slug being submitted during deformation to a higher temperature in the area of these great deformations than in the area of smaller deformations in order to produce areas with great deformations in its cross sectional shape.