A cost-effective way of forming certain metals into strong lightweight structures is by hydroforming. This can be done with aluminum, brass, low alloy steels and stainless steel.

Starting with a blank metal tube the tube expands into the desired shape when placed in a customized tool specifically designed for this purpose. The tool closes around the tube and the hydraulic rams are used to seal off the ends while water is forced into the interior of the tube.  You can see an animated hydroforming process here on this page, what is hydroforming.

When the required water pressure is reached the metal transforms into the shape of the mold. At the same time the hydraulic rams are computer-driven to each end of the tube so smooth, thick walls are formed as the metal expands turning it into attractive, repeatable shapes.Once the water is disposed of and the part removed the system moves on to the next blank tube.

Seven main benefits of hydroforming:

1. Much fewer welds are required

Previously, if wanted to transform metal into different shapes a lot of individual sections had to be welded together but hydroforming enables the metal tube to be turned into long, complex shapes with a reduced number of welds that reduces resistance and improves the efficiency of the airflow.

2. Few Steps in the Process

The whole process can be done in a much quicker time, often taking as little as 20 seconds for loading the blank tube to unloading the finished product. This is because many parts of the exhaust chain can be combined into one seamless assembly.

3. Remarkable Precision

The in-feeding of the material is accurately controlled by the computer while the metal is under high pressure inside the tool up to within 10 thousandths of an inch. This will be from 25,000 to 30,000psi.

4. Waste Reduction

By repeating the process you eliminate wastage from dented or accidentally bent parts and less material is needed due to the consolidation of the sections into one assembly.

5. Weight Reduction

Hydroforming produces lighter products as the required stiffness can be achieved using thinner walls. In previous processes this was not possible.

6. Form More Complex Shapes

Complex shapes can be achieved from pre-bent tubes by hydroforming and they can even have inlet and outlet openings incorporated.

7. Reduced Tool Costs

The number of tools can be reduced drastically due to fewer sections and the elimination of the burring and punching processes.

To get more information on hydroforming, contact us.

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