Abstract: A hydroforming apparatus capable of deforming relatively large and thick-walled workpieces, yet which is relatively small, simple, and inexpensive in construction and operation, includes a pressure vessel that is disposed within a frame. The pressure vessel includes upper and lower vessel members that support respective die sections therein. When the upper and lower vessel members are moved adjacent to one another, the die sections cooperate to define a die cavity in which a workpiece to be hydroformed is disposed. An inflatable bladder is disposed between one or both of the die sections and the associated upper and lower vessel members. During the hydroforming operation, pressurized fluid is introduced within the workpiece so as to expand it outwardly into conformance with the die cavity defined by the die sections. At the same time, pressurized fluid is introduced into the inflatable bladder, causing it to expand between the die sections and the associated upper and lower vessel members.

Abstract: The present invention provides an apparatus for shaping/embossing thin-walled work pieces, and is particularly apt for realizing complex and non-uniform shapes/designs in cylindrical metal container bodies. In one application, at least one pressurized fluid stream is ejected directly against one side of container body sidewall with a configured surface provided on the other side of the container body sidewall to achieve the desired shaping/embossing. At least one of the pressurized fluid stream and configured surface may be disposed for rotational and/or longitudinal motion. Such driven motion can be utilized to achieve progressive helical working of a cylindrical metal container body, thereby yielding the desired shaping/embossing.

Abstract: The method of forming SPF/DB structures having reinforcement webs that are constructed by welding two or more sheets together along an interrupted seam and placing the core so formed between two face sheets, expanding the face sheets into a die by providing pressurized inert gas through one of the face sheets and through a pressure equalization hole drilled through a sealed area formed by the seam, and using pressurized inert gas to expand the core sheets into webs that extend between the face sheets.

Abstract: A cradle assembly for a motor vehicle comprises a pair of spaced side frame members, a front cross frame member and a rear cross frame member. The front cross frame member is connected with front ends of the side frame members. The rear cross frame member extends between rear ends of the side frame members. The frame members are formed from tubular metal blanks by a hydroforming process in which each blank has fluid pressure provided internally thereto and thereby radially expanded so that the frame members have a peripheral configuration modified with respect to an original peripheral configuration of the associated blanks.

Abstract: A seat frame assembly for a motor vehicle comprises a seat frame and a seat back frame. The seat frame is constructed and arranged to have a seat cushion mounted thereon in overlying relation. The seat back frame is connected with the seat frame and has a pair of spaced metallic vertical support portions at opposite sides thereof, the seat back frame constructed and arranged to have a seat back cushion mounted thereon. At least one of the vertical support portions are formed from a pair of telescoping tubular blanks including an elongated inner metal blank formed into an integrally formed vertical member of the at least one vertical portion extending from a lower portion of the seat back frame connected with the seat frame to an upper end of the seat back frame and a relatively shorter outer metal blank formed into a sleeve rigidly secured in surrounding relation to the lower portion of the vertical support member.

Abstract: A superplastic forming (SPF) method using a self-contained die obviates the need for external containment bands or rings. The method and die are particularly advantageous for use in forming generally planar parts but may also be used to form parts of a more cylindrical shape. The die includes two or more die segments, each of which is unitarily formed from a suitable material such as graphite or ceramic. Each die segment has a unitarily formed connecting portion for interlocking it to another die segment. The connection portion may be a tab having a bore through which a pin may be extended to interlock the die segments. The die may swing open and closed in a hinged manner or be completely separable. In accordance with the method, a gas-tight preform assembly made of a metal such as titanium alloy is placed in the die. The die and preform assembly are heated in a vacuum furnace. Gas is injected into the preform assembly, expanding it to conform to the shape of the interior of the die.

Abstract: A metal tube is cold formed into a stamped member by filling the tube with a liquid change-of-state material, freezing the change-of-state material, sealing the tube containing the solid change-of-state material, and stamping the tube in a die. The change-of-state material compresses during the stamping step to force the walls of the tube to conform to the die cavity, eliminating the need to pressurize the tube prior or subsequent to stamping. Additionally, the solid within the tube provides support to the wall of the tube during a piercing step to form a hole in the tube having less deformation surrounding the hole than a comparative tube pierced without having the solid fill. After the stamping or piercing steps, the change-of-state material is melted and drained from the tube. Further, a tube is pierced by forming an outwardly bulged area and piercing the tube in the outwardly bulged area while sinultaneously depressing the tube to substantially flatten the outwardly bulged area.

Abstract: A high-pressure piping metal tube to be exposed to a high-pressure fluid on its inner face and having an increased number of service times, and a process for manufacturing the high-pressure piping metal tube. This high-pressure piping metal tube is made of a bent metal tube having a large thickness and a small diameter, in which a compressive stress is left in the inner face thereof. The high-pressure piping metal tube manufacturing process, comprises: the step of bending a metal tube having a large thickness and a small diameter; and the step of adding a residual compressive stress to the inner face of said metal tube.

Abstract: Unitary vehicle body compartment structures of the type comprising wall members and/or interconnected frame members that define the surface of a cylinder are made by providing a tube that is initially smaller than the cylinder and expanding at least portions of the tube to the shape of the body compartment structure. Functional openings such as windows are trimmed from the deformed tube to further define the compartment. A complete body may be assembled by attaching two or more such compartments such as, e.g., a passenger compartment, an engine compartment and a luggage compartment. Tube or tube segments may also be employed to make segments of the body compartment or smaller body parts such as doors and hoods.

Abstract: A method of manufacturing a metallic can body that is shaped distinctively in order to enhance its visual presentation to consumers includes, in one embodiment, steps of providing a can body blank that has a sidewall that is of a substantially constant diameter; providing a mold unit that has at least one mold wall that defines a mold cavity that is shaped generally like the can body blank, the mold wall having a pattern formed therein that corresponds to a desired final shape of the can body; positioning the can body blank within the mold cavity; and supplying a pressurized fluid into the mold cavity so that the can body blank is forced by pressure against the mold wall, causing the can body blank to assume the desired final shape of the can body.

Abstract: A frame assembly for a motor vehicle and method of manufacturing the same. The method comprises the steps of: forming a rearward frame module, forming a forward frame module, and forming a central frame module comprising a pair of longitudinal central frame siderails.

Abstract: Apparatus for mechanically and hydroform reconfigurating an elongated tubular workpiece in an elongated cavity between upper and lower tool subassemblies each composed of a plurality of independent tool segments movable axially, relative to the cavity axis, together or spaced from each other, and independently movable transversely of the cavity, usually vertically, in sequence, to grip the end portions of the workpiece while its ends are flared with tapered mandrels, and after the workpiece is filled with liquid, offset deform one workpiece portion while the tool segments are spaced apart and with axial infeed of workpiece material, then offset deform another portion with further axial infeed of workpiece material. Hydroforming pressure is then applied to partially expand the workpiece. Then after withdrawing segment spacing stops, forcing the tool segments together, and totally closing the tool, a greater hydroforming pressure is applied in the workpiece to expand it to the specific cavity configuration.

Abstract: To produce an elongate hollow metal body with a cross-sectional contour varying in the longitudinal direction by the internal high-pressure forming process in an internal high-pressure forming press, a sheet-metal blank composed of two blank parts of identical area is first produced, each part having, apart from additional joining-area parts provided in the region of the longitudinal edges, in the longitudinal direction at least the length of the longitudinal hollow body and in the transverse direction at most half the length of the respective cross-sectional contour. Subsequently, the two blank parts are laid one on top of the other and are joined together, in particular welded, in the region of the joining-area parts. Thereafter, the sheet-metal blank is expanded by introducing a pressure medium between the two blank parts held within a tool consisting of two dies.

Abstract: Unitary vehicle body compartment structures of the type comprising wall members and/or interconnected frame members that define the surface of a cylinder are made by providing a tube that is initially smaller than the cylinder and expanding at least portions of the tube to the shape of the body compartment structure. Functional openings such as windows are trimmed from the deformed tube to further define the compartment. A complete body may be assembled by attaching two or more such compartments such as, e.g., a passenger compartment, an engine compartment and a luggage compartment. Tube or tube segments may also be employed to make segments of the body compartment or smaller body parts such as doors and hoods.

Abstract: A metal tube is cold formed into a stamped member by tube is cold formed into a stamped member by sealing a tube containing liquid at approximately atmospheric pressure and then stamping the liquid-filled tube in a die. The pressure within the tube increases during the stamping step to force the walls of the tube to conform to the die cavity, eliminating the need to pressurize the tube prior or subsequent to stamping.

Abstract: An apparatus for high-pressure bulge forming of tubular workpieces has an upper die plate facing generally downward and extending at an acute angle to the vertical and a lower die plate generally parallel to and confronting the upper die plate. One of the plates is movable along an axis generally perpendicular to the plates toward and away from the other die plate. Respective upper and lower die halves carried on the die plates can fit together to form a die cavity having open ends and are adapted to receive a one of the workpieces with ends of the workpiece exposed at the open ends of the die cavity. The one die plate and the respective die half are displaceable toward and away from the other die plate. Respective actuators on the upper die plate have heads engageable with the ends of the workpiece in the die cavity and one head is formed with a passage for internally pressurizing the workpiece in the die cavity for bulge-deforming the workpiece.

Abstract: Apparatus and method for hydroforming a dual wall conduit having a controlled size gap between the walls, a frame having an upper crown and a lower bed defining a hydroforming space therebetween, the bed having a slideway extending from the space to a load-unload-preform position out of the space. A mold assembly on the slideway has a lower platen and an upper platen defining at least two hydroforming cavities, one cavity being an elongated preform and semi-finish cavity, and the other cavity being an elongated finish cavity. Mold shifting means is positioned for shifting the mold assembly on the slideway from the position in the space between the crown and bed, to and from the forward load-unload-preform position. Mold closing and preforming hydraulic cylinders are operably connected to the upper mold platen for closing the upper platen onto the lower platen and creating mechanical preforming on dual wall tubular stock in the preform and semi-finish form cavity.

Abstract: In an apparatus for molding particularly a tubular blank (1) of a ductile metal with internal high pressure in a mold, which has a cavity (5), a lower part (2) and a removable upper part (3) as well as a mechanism (6, 7, 13-21) for holding the upper (3) and lower parts (2) together, this mechanism consists of a pot (7), which is provided with a lid (15) and in which the mold (2, 3) is inserted. Between the pot (7) and the lid (15), a bayonet lock (13-20) is provided with a row of interlocking devices (14, 19), which can be brought into and out of engagement by means of a ring (16), which can be rotated relative to the mold (2, 3), and with an annular (9; 21) introduction of force into the lower part (2) and the upper part (3) near their circumference.

Abstract: In an apparatus for molding particularly a tubular blank of a ductile metal with internal high pressure in a mold having a cavity, which apparatus has a pressure-medium connection, which can be advanced from one base (10) and can be applied tightly against the one end of the tubular blank and a seal or a second pressure-medium connection, which can be advanced from a second base (11) and can be applied tightly against the other end, the mold or the pot (3) accommodating the mold has a circular cross section in the horizontal plane and, starting from the two bases (10; 11) with two tie rods (25; 26), a yoke (28; 29) is placed about the mold or the pot (3) and one (11) of the two bases can be moved on an arc (14) about the vertical axis (12) of the mold or the pot (3) and can be fixed at different places.

Abstract: A rail frame assembly for a motor vehicle comprises a rearward frame module having a pair of generally parallel rearward frame rail members interconnected by a rearward cross-member assembly. A central frame module includes a pair of generally parallel central frame rail members interconnected by a central cross-member assembly, the central frame members each having a generally U-shaped transverse cross-sectional configuration including a vertical base wall portion and a pair of outwardly extending generally parallel horizontal wall portions extending from opposite ends of the base wall portion. The U-shaped central frame members are each bent between two spaced positions thereof, and one of the horizontal wall portions extending from one end of the base wall portion has metallic grains therein substantially stretched at a location between the spaced positions.

Abstract: A method for hydroforming a tubular structural member of generally polygonal, flat walled cross section in which the various walls in the final part do not have the same thickness. A cylindrical tubular blank is extruded in which the outer surface is round, but in which the inner surface is asymmetrical, providing several contiguous angular sectors or portions of varying width and thickness. Each individual angular portion is tailored as to thickness and width to correspond to a respective wall in the final part. The blank is oriented between in a die cavity so as to align each angular portion with a respective wall of the finished part, and hydroformed in conventional fashion.

Abstract: An apparatus and method for forming a one-piece, complex-shaped tubular member from a tubular blank is provided. The tubular blank is placed in a die cavity defining a tube having at least two expanded portions and a bend therein. As the die cavity is closed around the tubular blank to form the bend, the interior of the tubular blank is pressurized to expand the tubular blank into the at least two expanded portions defined by the die cavity. When the bent and expanded tubular blank is removed from the die cavity, the ends of the tubular blank are cropped to form the finished tubular member.

Abstract: A method and apparatus capable of forming a dual tube conduit having a predetermined outer tube dimension, a predetermined inner tube dimension, and a predetermined gap between the tubes. A dual tube workpiece may be initially bent in one or more zones to a desired nonlinear configuration, the inner and outer tubes are hydroform expanded simultaneously to obtain the selected inner tube dimension, and the outer tube is then hydroform expanded to the desired outer tube dimension and to the desired gap therebetween, while the inner tube is held constant.

Abstract: A method for augmenting an apparatus with pumps and a high pressure multiplier in such a manner that the apparatus can be altered to perform as a draw die press, hydroform press, tube bender, and as a hydraulic bulge form press by utilizing appropriate quick change platens.

Abstract: Disclosed is apparatus and methods for the stretch forming of an elongated hollow metal section, such as an aluminum extrusion. The apparatus and methods use a flexible constraining means which surrounds at least a portion of the outer periphery of the elongated hollow metal section to constrain and support the walls of the elongated hollow metal section against the forces produced within the interior of the hollow metal section during the reshaping of the extrusion by the stretch forming operation. The apparatus and methods disclosed herein resist wrinkles, crimps and bulges being formed in the walls of the elongated hollow metal section during the stretch forming and reshaping thereof.

Abstract: This invention teaches a method for producing a tubular structural member which can longitudinally vary in wall thickness, perimeter and material using the hydroforming process. This is accomplished by first fabricating a tube blank of the desired longitudinal combination of wall thickness, perimeter and material by welding together portions of tubing having the desired characteristics and then hydroforming the resultant blank. The hydroformed part will have nearly the same thickness, perimeter and material characteristics as the blank in the corresponding longitudinal location.

Abstract: Disclosed is apparatus and a method for the stretch forming of an elongated hollow metal section, such as an aluminum extrusion. The apparatus and method uses one or more constraining means secured to the forming die and a die extension to constrain and support the walls of the elongated hollow metal section against the forces produced by air pressure within the interior of the hollow metal section. The apparatus and methods disclosed herein prevent the formation of wrinkles, crimps and bulges in the walls of the elongated hollow metal section during the stretch forming and reshaping thereof.

Abstract: A hollow workpiece having a tubular end portion is deformed by first fitting the workpiece into a die formed with a cavity adapted to receive the workpiece with the end portion of the workpiece projecting along an axis out of the die and then engaging over the projecting end portion of the workpiece a feed sleeve in a pressure-tight fit. The sleeve and workpiece are supported relative to each other such that the holding portion can slide in the sleeve and that the sleeve exerts substantially no axial force on the workpiece. Then an interior of the workpiece is pressurized through the sleeve and to deform the workpiece outward against an inner surface of the die.

Abstract: An apparatus for pressure deforming a hollow workpiece having a tubular end portion has a die formed with a cavity adapted to receive the workpiece with the end portion of the workpiece projecting out of the die and a fitting movable along an axis toward and away from the die and formed with a seat sealingly engageable in a feed position over the projecting end portion of the workpiece. An annular self-tightening gland in the seat circumferentially engages in the feed position around the projecting end portion of the workpiece. A passage opening in the seat into the hollow workpiece when the fitting is engaged over the projecting end portion serves for pressurizing an interior of the workpiece and thereby deforming it outward against an inner surface of the die and for pressing the gland radially tightly against the workpiece and against the fitting.

Abstract: A seal device for a hydroforming press includes a housing having a cylindrical bore and a cylindrical seal carrier slidable within the housing bore. The seal carrier has a bore and a tube support which fit closely on outside and inside of the end of the tube to be hydroformed. An actuator is operable to forcibly move the seal carrier from a retracted position withdrawn away from the end of the tube to an extended position in which the seal carrier is installed over the end of the tube. A resilient elastomeric annular seal is carried by the seal carrier and encircles the outer circumference of the tube with some clearance. A seal actuator carried on the seal carrier compresses the seal upon relative movement between the seal actuator and the seal carrier so that the seal is forced radially inwardly to seal against the tube.

Abstract: An elongate tubular member with a seamless frusto-conical interior wall surface having a selected taper angle of typically 5.degree. or less which is formed from a metal tubular member of ductile material and circular wall cylinder configuration by the process of sequentially expanding contiguous length segments of the ductile tubular member to an interior frusto-conical wall configuration. The process involves inserting the tubular member into a female die member which defines an interior frusto-conical surface with a selected cone angle of typically 10.degree. or less with the tubular member coaxially aligned with the die member interior surface.

Abstract: An autofrettage device for a tube includes thrust bearings for receiving opposite ends of the tube. A mandrel is introducible into the tube and includes a sealing arrangement for sealing an annular gap between the mandrel and an inner wall of the tube against escape of a pressure medium supplied to the annular gap. A mandrel holder including a ball joint socket supports the end of said mandrel so that the mandrel is pivotally movable relative to the mandrel holder.

Abstract: A method of forming a tubular, double wall, air gap, exhaust duct component for an internal combustion engine, the resulting exhaust duct component, and the blank for such, involving providing an inner membrane duct element, with orifices therethrough spaced along its length, providing an outer structural duct element in 360 degree engagement with the inner duct element in the areas where forming and bending operations are to be performed, conducting such forming and bending operations, securing the resulting blank in a hydroforming die cavity, sealing the ends of the inner element to the ends of the outer element, plugging the ends of the inner element, injecting a liquid, preferably water, into the inner duct element and increasing the pressure on the liquid to expand the outer element away from the inner element and ultimately into conformity with the die cavity while the inner element floats in place, in a manner to create an air gap substantially over the full length of the duct component, i.e.

Abstract: A process for allowing the attachment of drive or coupling elements, such as cams, gears, crank webs or bearing elements, such as friction bearing bushes, or complete roller bearings on tubes or tubular portions by hydraulic expansion, for the purpose of producing assembled cam shafts, transmission shafts, crank shafts or the like, with the expansion of the tubes taking place exclusively in the region of the respective elements beyond the limit of elasticity of the tubes, against a permanent elastic prestress in the elements. To relieve the load on the seals limiting the regions to be expanded, a counter pressure which is higher than the ambient pressure is applied to the intermediate or end regions.

Abstract: A process for producing hollow one-piece elements having a highly curved lateral wall from metal, in particular copper or copper alloy, pipes. A cylindrical pipe is widened via permanent deformation between two appropriately shaped dies, by simultaneously applying hydraulic pressure directly inside the pipe and axial pressure on the opposite ends of the pipe; the required finished shape being achieved in successive stages, by inserting inside the dies molds having a predetermined profile and of gradually increasing size.

Abstract: A bellows pipe is manufactured from a raw pipe, with an elastic body pinched between a movable core and a fixed core inside the raw pipe, by compressing the elastic body by axially moving the movable core to form an annular convex portion in the raw pipe, changing the annular convex portion to a bellows portion by axially moving a punch to press the annular convex portion, pinching the bellows portion between a chuck and a chuck inner block assembled therein, shifting the pipe a given distance by axially moving the chuck and chuck inner block holding the bellows portion therebetween, and repeating the foregoing steps. Therefore, a small-diameter raw pipe of smaller than 16 mm diameter can be deformed, the outer diameter, pitch, etc. of a bellows portion can be freely set, the elastic body is worn little.

Abstract: An improved method and apparatus for repairing a subsea pipeline. The improved apparatus includes a forming tool having a body, a resilient sleeve surrounding the body, means for delivering fluid under pressure through the body to the interior of the resilient sleeve, a frame, an arm connected to the body of the forming tool and connected to a pressure responsive actuator supported from said frame to extend and retract the forming tool, a collet connector supported from said forming tool, a forming sleeve, the frame having means for supporting itself on the sea bottom, said collet connector being initially connected to said forming sleeve, means for controlling the supply of fluid under pressure to opposite sides of said actuator, means for injecting a fluid from said body into the space within said annular connecting means, and means on said frame for connecting lines thereto.

Abstract: Hollows are hydraulically widened as their ends are closed by sealing heads which include inflatable sealing rings bearing against the hollow at a pressure that is always in excess of the widening pressure applied to the hollow.

Abstract: In order to prevent a probe (2) used for expanding tubes (1) in portions from having an uneven effect due to its eccentric position in a tube which is not completely straight, the probe given a slightly flexible design is provided with centering rings (11, 13) which flexibly rest on both the inner face of the tube and on the probe member. The flexible parts (7) of seals limiting the operational regions (8), along their circumference, then evenly and simultaneously contact the inner wall of the tube. Several designs for the centering rings are possible. To facilitate their introduction into the tube, the process of introduction is accompanied by a process of lubricating the inner tube parts, a process which improves sliding and for which the hydraulic fluid required in any case may be used.

Abstract: A method for forming projections on the periphery of a pipe in order to provide branch pipes, such as a manifold for automobiles, is characterized in that the branch pipes are formed by a bulging process to have a predetermined thickness without thinning. A first embodiment includes the step of indenting a pipe member by press work or the like, at locations close to the position of a projection which is to be formed, in a preliminary deforming process. The deformed pipe member is then placed in a bulge mold having a recess or space, with the pipe member being positioned so that the indentations in the pipe member lie adjacent the recess in the bulge mold. Pressurized fluid is then introduced into the interior of the pipe member to bulge the wall of the pipe member into the recess in the bulge mold. A second embodiment employs a bulge mold having fixed recesses or spaces and variable recesses or spaces for forming a plurality of projections.

Abstract: In a method of explosively expanding a tubular metal component into engagement with a surrounding metal component, an explosive charge is disposed axially and fired in an insert having a hollow cylindrical container fitting closely within the portion of the tubular metal component to be expanded and having charge holding device, for example an axial pocket, to accommodate the explosive charge, the container being filled with a shock wave-transmitting liquid. Compared with solid inserts, the novel hollow insert is cheaper and requires a smaller explosive charge for a given operation. The method is especially advantageous for expanding large diameter tubes.

Abstract: An apparatus for joining two tubular members together at a subsea location wherein one of the tubular members has internal grooves and the second tubular member is sufficiently small to slide into the first tubular member and the first tubular member has an external flange suitable for connecting to a flowline, which apparatus includes a tubular mandrel having means for connecting to said first tubular member, a resilient sleeve surrounding said mandrel and adapted to be positioned within said second tubular member, volume compensating means positioned within each of said grooves and testing means carried by said mandrel to allow testing of the joint while the mandrel is still in position after forming.

Abstract: A method for forming branch pipes on the periphery of a pipe, such as a manifold for automobiles, is characterized in that the branch pipes are formed by a bulging process to have a predetermined thickness without thinning. A first embodiment includes the step of indenting a pipe member by press work or the like, at locations close to the position of a projection, in a preliminary deforming process. A second embodiment employs a bulge mold having fixed spaces and variable spaces for forming a plurality of projections. The second embodiment includes the step of bulging the pipe material into the fixed spaces while the variable spaces are occupied by detachable members, and the step of removing the detachable members from the mold and then bulging the pipe member again.

Abstract: A box-like frame member is formed by compressing an internally-pressurized tubular blank within a die having a cavity conforming to the final box-like cross section desired for the product, and increasing the pressure to exceed the yield limit of the wall of the blank to expand the blank into conformity with the die cavity. The blank is selected so that the final product and the die cavity have a circumference preferably no more than about 5% larger than the circumference of the blank, to avoid weakening or cracking of the blank through excessive circumferential expansion. The internal pressure forces the blank evenly into the corners of the die on closing and allows the blank to be confined within the die without sections of the die pinching the blank on closing of the die.

Abstract: An apparatus for securing straight tubes between two tube sheets in a pressure-tight manner, especially in the manufacture of heat exchangers. Tubes are inserted, with play, in bores of the tube sheets. One end of each tube is hydraulically expanded via a pressure medium to thereby press this one end against the associated tube sheet. The one end is secured to the associated tube sheet, preferably by being welded thereto. Each tube is heated in conformity with a prescribed prestress that is to be produced in secured ones of the tube to take into account subsequent operation conditions to push a portion of the non-secured other end of the tube out of its associated tube sheet until a predetermined difference in length between the cold and heated-up states of the tube is pushed out.

Abstract: The invention relates to an apparatus for the continuous production of pipes with cross-profiled walls from a pipe strand of thermoplastic plastic emerging in still plastic state from an extrusion nozzle.

Abstract: A hollow sphere is made of a superplastic material and blown to a large size, unrestricted or with restriction in one or two directions. The unrestricted hollow sphere may be rotated while being blown.

Abstract: A cam shaft made from lobes having irregularly shaped apertures spaced along the longitudinal axis of a hollow tubular shaft. The method of making the cam shaft includes the steps of: inserting a hollow tubular shaft through the apertures of a plurality of the lobes axially and radially with respect to the longitudinal axis of the shaft. The method is characterized by flaring at least a first end of the shaft and backing the exterior of the first flared end to prevent axial radial movement thereof. In addition, a plug means is inserted into fluid sealing engagement with the interior of the first flared end to sandwich the flared end against the backing of the exterior thereof. The hollow shaft is filled with liquid and the opposite ends of the shaft are clamped between the plug means at the first flared end and a fluid sealing means at the opposite end of the hollow shaft. Hydraulic force is then applied to the interior of the shaft to expand the hollow shaft into engagement with the apertures of the lobes.

Abstract: Method and apparatus therefor for forming an inner tube and turbulator for a concentric tube heat exchanger from a stock length of tube comprising the steps of simultaneously mechanically forming a bell-shaped sealing and outer tube attaching section in the ends of the tube while also sealing the ends, applying hydraulic pressure to the interior of the tube to form outwardly projecting turbulator bumps in the tube at places located about and along the length thereof, and increasing the mechanical forming force with increasing hydraforming force so that the latter opposes the former and only their net force acts on the bell-shaped sections to maintain the sealing during the hydraforming to prevent coining of these sections.

Abstract: A box-like frame member is formed by compressing an internally-pressurized tubular blank within a die having a cavity conforming to the final box-like cross section desired for the product, and increasing the pressure to exceed the yield limit of the wall of the blank to expand the blank into conformity with the die cavity. The blank is selected so that the final product and the die cavity have a circumference preferably no more than about 5% larger than the circumference of the blank, to avoid weakening or cracking of the blank through excessive circumferential expansion. The internal pressure forces the blank evenly into the corners of the die on closing and allows the blank to be confined within the die without sections of the die pinching the blank on closing of the die.