Hydroformed Structures are Lighter and Stronger
Hydroformed structures offer a lighter and stronger alternative to traditional stamped and welded assemblies.
Automobile designers have discovered that hydroformed structures are a lighter and stronger alternative to traditional stamped and welded assemblies. American Hydroformers, Inc. (AHI) (Fort Wayne, IN) is offering hydroformed catalytic converter cones and exhaust components, crash tips, cross members, engine cradles, frame rails, header and exhaust manifolds, instrument panel beams, radiator and roof supports, trailing suspension arms and more.
For many years, high-performance and racecar builders have utilized tubular frame construction for its strength and lightweight nature. With the latest federal mandates for mileage and crash worthiness, hydroformed frames provide an alternate solution.
“To achieve the goal of stronger, stiffer and lighter demanded by more fuel efficient automobiles, hydroformed structures are the way to go,” says Todd Ellinger, vice president of sales and marketing for AHI. He adds, “Hydroformed components will also benefit electric and hybrid vehicles. We work closely with OEMs to create the products they need at a competitive price.”
A simplified overview of the hydroform process is as follows: Raw tube is loaded into hydroforming dies and the hydroforming press closes. The sealing rods engage the part, seal the ends and fill it with water, increasing pressure inside the part. The sealing rods push the tube into the die (end feed) and the internal pressure is ramped to its maximum value. The hydroformed part takes on the shape of the die. Then, the final hydroformed part is removed.
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About the Author: John Dymale
