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: Methods for making skin panels suitable for use in aircraft structures and fuel tank structures, such as fuselages and reusable launch vehicle propellant tanks. A first method includes the following steps: machining a starting plate to a final part geometry; and explosive forming the machined plate to at least one of a uniaxial curvature and a biaxial curvature. A second method includes the following steps: explosive forming a starting plate to at least one of a uniaxial curvature and a biaxial curvature; and machining the curved plate to a final part geometry. Accordingly, the invention enables making integrally stiffened unitized axial load carrying skin panels that are either uniaxially or biaxially curved.

Abstract: To manufacture an axially collapsible driveshaft assembly, first and second tubular members are disposed in an axially overlapping relationship. Central portions of the concentric tubular members are then deformed into conformance with a die cavity having a non-circular cross sectional shape. The deformed first and second tubular members are then cut to provide two pairs of outer and inner tubular sections. Next, the outer tubular sections are removed from the associated inner tubular sections, and the inner tubular sections are oriented such that the deformed portions thereof are aligned with the deformed portions of the outer tubular sections. Lastly, the deformed portions of the inner tubular sections are inserted within the deformed portions of the outer tubular sections to form a pair of axially collapsible driveshaft assemblies.

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: An electromagnet assembly for supplying a region of concentrated electromagnetic flux is provided. The assembly includes a flat strip of an electrically conductive metal. The strip has a first and a second opposite planar surfaces at least one of which is covered by a dielectric material. The strip has first and second end portions. The strip is wound in a coil including at least one first loop and one second loop and disposing the second opposite planar surface in the first loop substantially-adjacent the first opposite planar surface in the second loop. The coil is disposed about an axis of symmetry configured to concentrate electromagnetic flux at a midpoint on the axis of symmetry. First and second electrical terminals are connected at the first and second end portions, respectively.

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: A method of making combustion turbine transition duct bodies without longitudinal welds by hydroforming two duct bodies back to back with bellows thrusters secured to the duct body open ends. This enables the manufacturing of duct bodies with detailed features and high pressure without using compression cylinders. Multi-layer transition duct bodies can also be assembled with layers of different materials, for example, having a heat-resistant layer inside and high strength layer outside. They can be assembled using cold shrinking and heat expanding. In addition, anti-fretting and anti-vibration coatings can be applied between the layers for improved performance.

Abstract: An apparatus for exposing a pipeline to a high internal pressure of the order of 1000 to 15000 bar, having at least a first, substantially stationary receiving device for a first end of the pipeline and a second receiving device for a second end of the pipeline, wherein the second receiving device is arranged so as to be spatially freely adjustable.

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: In a method and a device for creating a hole on the outer circumference of a hollow profile which is circumferentially closed and under an internal high pressure, before hole-punching, a punch which is integrated in the internal high pressure forming mold such that it can be guided butts against the location of the hole to be created. When it leaves its position of abutment, the punch creates a punched slug there alongside the hole. To make it possible for holes to be punched at virtually any desired location in hollow profiles in the internal high-pressure forming mold in a simple way, it is proposed that the hole-punching takes place by the punch being moved in the guiding bore of the forming mold by the internal high pressure acting together with a driving element, the body axis of which lies approximately at 90° in relation to the hole punch axis and which for its part is driven in a rotary manner and/or translatory manner in the axial direction.

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 process for the production of tubular structural parts fabricated from PGM materials and having circumferential undulating bulges by forming from smooth-walled tube pieces. A smooth-walled tube piece (1) is inserted into a cylindrical forming die (2) with an internal diameter that corresponds substantially to the external diameter of the tube piece and that has radial undulating recesses (3). This die is provided at both axial ends with a press tool (4,5) that tightly seals the tube ends. The space that is thus formed is completely filled with an hydraulic fluid (6), and an hydraulic internal pressure is then produced by exerting an axial compression via the press tools (4,5) in such a way that under simultaneous shortening of the tube piece bulges (7) are formed in the wall of the latter that correspond to the recesses (3) of the forming die (2).

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 for electromagnetically forming a metallic member includes deforming an end of a metallic member by electromagnetic forming, pressing the outer surface of the deformed end on the surface of a mold to form a flange having a predetermined shape at the end of the metallic member and, at the same time, work-harden the flange. The method is capable of forming a flange having a shape corresponding to the shape of the outer surface of another member to be joined to the metallic member at an end of the metallic member with high dimensional accuracy and shape accuracy and secured joint strength.

Abstract: A device for punching work pieces in an internal high-pressure forming tool includes a punching die guided displaceably in a bore of the forming tool. The device also contains a drive with which the punching die is moved back and forth between the in-use position and the non-use position. In order to facilitate, in a simple and space-saving manner, the punching of work pieces in the internal high-pressure forming tool, the drive contains a pressure fluid and a pressure transfer device that can be elastically expanded via the pressure fluid between a base firmly attached to the tool and a punch head of the punching die. The pressure transfer device abuts a partition at least indirectly at the punch head.

Abstract: An electromagnet assembly for supplying a region of concentrated electromagnetic flux is provided. The assembly includes a flat strip of an electrically conductive metal. The strip has a first and a second opposite planar surfaces at least one of which is covered by a dielectric material. The strip has first and second end portions. The strip is wound in a coil including at least one first loop and one second loop and disposing the second opposite planar surface in the first loop substantially adjacent the first opposite planar surface in the second loop. The coil is disposed about an axis of symmetry configured to concentrate electromagnetic flux at a midpoint on the axis of symmetry. First and second electrical terminals are connected at the first and second end portions, respectively.

Abstract: A hydrotapping power unit is disclosed that is operable to position and hold a hydrotapping tool in a home position adjacent a part while the part is being hydroformed in a die cavity, to then advance the tool to pierce a hole in the hydroformed part while the part remains in the die cavity and under pressure and then continue to advance the tool to inwardly extrude the part about the hole, to then further advance while also rotating the tool so that the tool is fed at a feed rate equal to the thread pitch of the tool to thereby form a thread in the pierced hole, and finally to retract while also rotating the tool but in the reverse direction and at the same feed rate to release the tool from the threaded hole.

Abstract: A method of superplastically forming a workpiece comprises placing the workpiece (16) in a die (14) and heating the workpiece (16) to a temperature at which the workpiece (16) is superplastically formable. Pressure is applied to the workpiece (16) to superplastically form the workpiece (16) to the shape of the die (14). The temperature of the workpiece (16) is measured and is analysed to determine the measured temperature distribution of the workpiece (16) at stages in the superplastic forming process. A database of desired temperature distributions of the workpiece (16) at different stages in the superplastic forming process is kept.

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: The present invention is directed to a method and a device for clinching metal sheets disposed one over the other in planar fashion. A joining tool, composed of a punch and a die having an anvil, is used to jointly displace metal sheets, profiles, or multi-sheet connections, out of the sheet-metal plane, under the action of forming energy introduced by ultrasound, compressing and integrally connecting the same.

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: Process for producing a tubular component which comprises sections which are intentionally different from one another with regard to one or more aspects selected from the group consisting of aspects including material, thickness, size, more specifically circumference or diameter, and the like, and hydroforming of the component, in which process the component is produced by rolling up a substantially flat sheet, which flat sheet substantially corresponds to a flat blank of the tubular component.

Abstract: A method and apparatus for subjecting a material in a liquid to explosive force is provided. The method and apparatus involve a vessel having a length greater than it width. The vessel has a top which is quickly and easily lockable and removable so as increase the material processing rate of the vessel.

Abstract: A device and a method for generating intense and brief variations of magnetic pressure, predetermined and controlled, capable of being isentropic inside a sample (23) of solid material. An electromagnetic cell (1) includes a flat parallel line of conductive material having two branches (4, 5) in the form of planar plates, of similar shapes and dimensions, separated from each other by a distance of not more than 3 mm, one of which (4) bears the sample (23) rigidly fixed on the branch (4), the two branches (4, 5) being electrically connected to each other by an end junction strip (7), and electrically connected, opposite the end junction strip, to elements (2, 3) generating electric current pulses so as to produce in less than 500 ns an electric current flowing in the electronic cell (1).

Abstract: While a workpiece is heated and pressed by one of a pair of high-pressure vessels, a workpiece being pressed by the other high-pressure vessel is placed in a heated state. In the reducing process after termination of heating and pressing treatment of the workpiece by one high-pressure vessel, both the high-pressure vessels are placed in communication, and the pressure medium gas released from one high-pressure vessel is poured into the other high-pressure vessel. After pressures of both the high-pressure vessels have assumed a nearly balanced state, the pressure medium gas is sucked out of one high-pressure vessel by a compressor and pressed, and is poured into the other high-pressure vessel, and the workpiece is heated and pressed by the other high-pressure vessel. By the method as described, considerable shortening of cycle time of HIP treatment is achieved, and the HIP treatment can be carried out with high efficiency.

Abstract: A mechanical transducer induces liquid cavitation, causing pressure waves in a liquid which are applied against a metal surface to afford localized elastic and plastic tensile microstrain. The pressure waves alter the surface tensile stresses in the treated metal by reducing the tensile stresses or forming surface compressive stresses. A boot is provided about the operating face of the transducer for confining a liquid through which compression waves are generated and applied to the metal surface, the boot sealing about the transducer and the surface undergoing treatment.

Abstract: In a method of fabricating a bellows by bulge forming, an annealing step is carried out during the bulge forming process of the bellows so that the capability of the material to elongate is recovered, and the workability of the bellows is improved in effect. In particular, the ratio of the outer diameter to the inner diameter can be made greater than a value that can be achieved by a single forming step. Therefore, the deflection (stroke) of each annular bulge or pleat can be increased for a given stress or the number of annular bulges and the length of the bellows can be decreased for a given stroke of the bellows.

Abstract: An isostatic press and the process of using same is disclosed and claimed. The isostatic press includes a yoke; a bottom cover affixed to the yoke; a top cover affixed to the yoke; and, a body moveable between a first position and a second position. A process for isostatically pressing a workpiece in the isostatic press is also disclosed and claimed. The process includes the steps of: placing the workpiece on the bottom cover; moving the body from the first position to the second position; pressurizing the chamber; depressurizing the chamber; removing the workpiece; and, moving the chamber from the second position to the first position.

Abstract: An electromagnet assembly for supplying a region of concentrated electromagnetic flux is provided. The assembly includes a flat strip of an electrically conductive metal. The strip has a first and a second opposite planar surfaces at least one of which is covered by a dielectric material. The strip has first and second end portions. The strip is wound in a coil including at least one first loop and one second loop and disposing the second opposite planar surface in the first loop substantially adjacent the first opposite planar surface in the second loop. The coil is disposed about an axis of symmetry configured to concentrate electromagnetic flux at a midpoint on the axis of symmetry. First and second electrical terminals are connected at the first and second end portions, respectively.

Abstract: In a system and method for bulge forming an article including a shaped portion from blank stock, the system includes a cage section adapted to enable the blank stock to be positioned and enclosed therein, and a die element, for enabling the shaped portions of the article to be formed thereagainst, adapted to be enclosed in the cage sections. The system further includes a flexible member, adapted to be enclosed in the cage sections, and to bulge therein upon the application of pressure to the flexible member. The flexible member is also adapted to push into and exert pressure on the blank, and to bend the blank relative to the die element to form the shaped portion of the article. The system also includes a flexible tube, for enabling expansion of the flexible member upon pumping a pressure exerting medium therethrough into the flexible member, to exert pressure on the blank and form the shaped portion of the article against the die element.

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: Method of joining a rod-shaped heating element with a tubular carrier element involving attaching a cylindrical carrier ring to the rod-shaped heating element using a magnetic forming process and inserting the carrier ring and the rod-shaped heating element into the tubular carrier element such that the outer circumferential surface of the carrier ring contacts the inner circumferential surface of the tubular carrier element.

Abstract: Methods for making skin panels suitable for use in aircraft structures and fuel tanks structures, such as fuselages and reusable launch vehicle propellant tanks. A first method includes the following steps: machining a starting plate to a final part geometry; and explosive forming the machined plate to at least one of a uniaxial curvature and a biaxial curvature. A second method includes the following steps: explosive forming a starting plate to at least one of a uniaxial curvature and a biaxial curvature; and machining the curved plate to a final part geometry. Accordingly, the invention enables making integrally stiffened unitized axial load carrying skin panels that are either uniaxially or biaxially curved.

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: Superplastic forming tools and method in which pairs of stacked metal blanks are serially loaded between heated forming dies that are moved to a closed position on each of the pair of blanks so that a partial perimeter gas seal is established therebetween. A pressure wedge is then introduced between the two blanks along one edge of the pair to act as a stopper or air seal to complete perimeter sealing thereof. The pressure wedge also establishes the operative position of a gas injection port, which directs pressurized air interiorly of the completed perimeter seal of the pair of blanks to force the blanks in opposite direction for the superplastic forming of a pair of discrete parts. The wedge and forming dies are then opened for the removal of a pair of formed parts and for the subsequent loading of additional pairs of stacked sheets for their simultaneous superplastic forming into pairs of parts.

Abstract: While a workpiece is heated and pressed by one of a pair of high-pressure vessels, a workpiece being pressed by the other high-pressure vessel is placed in a heated state. In the reducing process after termination of heating and pressing treatment of the workpiece by one high-pressure vessel, both the high-pressure vessels are placed in communication, and the pressure medium gas released from one high-pressure vessel is poured into the other high-pressure vessel. After pressures of both the high-pressure vessels have assumed a nearly balanced state, the pressure medium gas is sucked out of one high-pressure vessel by a compressor and pressed, and is poured into the other high-pressure vessel, and the workpiece is heated and pressed by the other high-pressure vessel. By the method as described, considerable shortening of cycle time of HIP treatment is achieved, and the HIP treatment can be carried out with high efficiency.

Abstract: A process and system for manufacturing a built-up camshaft by which the operational safety of the camshaft is ensured in a simple manner in any engine operation and the camshaft can arbitrarily be adapted to abutments which have different positions because of the individual engine construction. At least one cam is pushed onto a hollow shaft, after which the hollow shaft is expanded between the two faces of the cam which extend transversely with respect to the longitudinal course of the hollow shaft and at the respective bearing point by means of a highly pressurized pressure fluid. This fluid is delivered by a lance-shaped probe introduced into the hollow space of the shaft. On the one hand, a press fit occurs between the cam and the hollow shaft and, on the other hand, a bulging of the bearing point of the hollow shaft occurs which bridges the distance between the hollow shaft and the abutment.

Abstract: An apparatus for forming a generally planar metal plate into a dish with a three-dimensional pattern is provided. The apparatus comprises a mold having a forming surface with a contour corresponding to said three-dimensional pattern, and having edges corresponding to boundaries of the dish, which edges are defined by side walls essentially perpendicular to the forming plane; a forming device comprising a fluid basin and pairs of electric discharge members within the fluid and having an opening facing the mold to allow transmission of a pressure wave from the fluid to the metal plate; and an electric discharge circuitry for discharging a short and intense electric current through the pairs of electric discharge members generating an electric spark or breakdown within the fluid to yield formation of plasma, vapor or both.

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: 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 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 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 pressure vessel has a cylindrical side wall and a closed end joined to the side wall at a knuckle. The fatigue resistance of the pressure vessel is improved by autofrettage which moves a region of peak stress from the internal surface of the vessel to a region within the knuckle. Preferred are pressurized gas vessels of 6000 or 7000 series aluminum alloys.

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: Rare earth metal switched magnetic devices that comprise one or more magnets, a rare earth metal element positioned in the magnetic field produced by the magnet(s) and a system for controlling the temperature of the rare earth metal element are disclosed. The rare earth metal element is formed of a rare earth metal or rare earth metal alloy having magnetic properties that change from ferromagnetic to paramagnetic when heated above the Curie temperature of the chosen rare earth metal or rare earth metal alloy. Preferably the Curie temperature of the chosen rare earth metal or rare earth metal alloy is at or below the ambient temperature in which the rare earth metal switched magnetic device is to be used—approximately room temperature (70° F.) in the case of devices intended for use in a factory. Tailored Curie temperatures can be obtained by alloying rare earth metals together and/or with conventional switchable “soft” magnetic metals—iron, nickel, and cobalt.

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: In an inertia-press-fit method in which a kinetic energy is applied to at least one of two members in a direction which causes the two members to approach each other, and the two members are press-fitted with each other, an end surface 80 of the first member 10 and a bottom surface 82 of the second member 12 are caused, for stabilizing a relative position of the two members at a time when the press-fitting ends, to butt each other to define the relative position of the two members 10, 12 at the time when the press-fitting ends and, immediately after the butting, at least one of the two members 10, 12 is caused to plastically deform and thereby absorb a remaining kinetic energy of the one of the two members. Thus, the relative position of the two members 10, 12 when the press-fitting ends is stabilized.