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Archive for the Metal Fabrication Category

3 Myths About Deep Draw Metal Stamping

3 Myths About Deep Draw Metal Stamping

Over the course of many years, there have been numerous misconceptions about deep draw metal stamping and how the deep draw process works. For those who are unfamiliar with the deep draw metal stamping process, this is a manufacturing process that remains in competition with others in order to create a product that has a few similarities or one that is completely the same. However, the deep draw metal stamping process has a few major differences that separate it from the other methods and processes. 

What Is Friction Stir Welding? American Hydroformers

What Is Friction Stir Welding? American Hydroformers

The welding technique, friction stir welding, was developed almost 30 years ago in 1991. Although it was invented many years ago, it has seen a high rise in demand over the past few years. One of the main reasons that friction stir welding has seen such a massive increase is due to the rising demand for greater strength and durability in applications.

Friction Stir Welding: What is it and How Does it Work?

Friction Stir Welding: What is it and How Does it Work?

Lauded as the most significant innovation in metal joining in the last decade, Friction Stir Welding (FSW) introduces a solid-state joining process that is environmentally friendly, versatile, and energy efficient. FSW outperforms conventional fusion welding by joining aerospace aluminum alloys, and other metallic alloys, that are high-strength. The significance of this advancement is that aerospace aluminum alloys, like 2XXX and 7XXX series, have been classified as virtually non-weldable with conventional welding processes because of porosity and microstructure solidification behavior. Resistance welding can be performed on aluminum alloys, however, surface preparation has to be performed, which is expensive and surface oxide becomes a problem.

Why You Can Trust Us with Your High-Temperature Metal Gas Forming

Why You Can Trust Us with Your High-Temperature Metal Gas Forming

Here at American Hydroformers, we pride ourselves in keeping current with industry trends. That is just one of the many reasons why people to trust us with their high-temperature metal gas forming needs.

Where Would We Be Without High-Temperature Metal Gas Forming?

Where Would We Be Without High-Temperature Metal Gas Forming?

Although your average American probably has not heard of high metal gas forming, that does not mean they have not taken advantage of products made possible (or made better) through it. Those of us in the industry know better. We recognize that the vast majority of us would lead less comfortable and convenient lives without high-temperature metal gas forming. 

The Automotive Industry and High-Temperature Metal Gas Forming

The Automotive Industry and High-Temperature Metal Gas Forming

Although the process of high-temperature metal gas forming may not be common knowledge, most people benefit from this process on a daily basis. They just don’t know that they do.

Higher Value Increases Use of Aluminum in Vehicles

Higher Value Increases Use of Aluminum in Vehicles

In 2015, Ford’s F-150 was the first high-volume vehicle produced with an aluminum frame, reducing the F-150’s weight by 700 pounds. Since then, the need for strong, lightweight material is driving a significant increase in the use of hydroformed aluminum to make automobiles that are both fuel and cost efficient while retaining key safety features.

A New Way of Doing: High-Temperature Metal Gas Forming

A New Way of Doing: High-Temperature Metal Gas Forming

The birth of hydroforming has brought with it many advantages. When compared to mainstream production techniques, hydroforming has proved itself to be effective, quick, reliable and capable of outperforming products manufactured with standard conventional processes. Nevertheless, the close counterpart of hydroforming, high-temperature metal gas forming, is on the rise and has shown itself to be just as powerful. 

American Hydroformers Employs Faro Edge Scan Arm HD

American Hydroformers Employs Faro Edge Scan Arm HD

At American Hydroformers we recently obtained and implemented a new Faro Edge Scan Arm HD that enables enhanced product development, inspection, and quality control. As a 3D scanning and probing device, the Faro Edge Scan Arm HD provides capabilities such as rapid prototyping, reverse engineering, 3D modeling and rapid point cloud collection and comparison. Ideal for scanning challenging materials, the Faro Edge Scan Arm HD also allows for contact and non-contact measurements.

  • Rapid Scanning Speed
  • High Definition Data
  • Up to 2,000 Points per Scan Line
  • Fast Frame Rates
  • Scan Challenging Materials
  • Highly Accurate and Repeatable
  • Contact & Non-Contact Measurements

Acquiring this new Faro Edge Scan Arm HD will allow American Hydroformers to probe virtually any part or tube and collect all of the data needed to reproduce it.  With up to 2,000 actual points per scan line, extreme resolution and high accuracy, we are able to reproduce even the most intricate parts and components. The actual setup of the scanning arm features an extra wide scan stripe as well as fast frame rates. This allows for increased productivity with the large coverage area and the reducing scanning times.

Autoform Hydro Simulation

In addition to the Faro Edge Scan Arm HD, our in-house capabilities also include the utilization of AutoForm Hydro simulation software as well as FEA simulations. Our team of engineers are trained and regularly updated on this software which provides a comprehensive understanding and analysis of the entire hydroforming process. By employing this software in-house and utilizing the simulation process, we supply our customers with rapid verification, shorter development time, and improved process reliability.

  • Easily Identify Forming Issues
  • Rapid Tool Design
  • Accurate Springback Simulation
  • Quality & Cost Improvements
  • Reduced Development Time
  • Improved Reliability
  • Lower Material & Production Costs

By enabling better price controls and reduced tooling expense, American Hydroformers provides a cost-effective source for part production. Unlike other metal forming techniques, hydroforming allows for increased part strength, lower part weight, and greater design flexibility, while also improving overall part quality. Contact American Hydroformers to see how you can reduce your tooling and part costs.

How Tube Hydroforming Can Help Cafe Standards?

How Tube Hydroforming Can Help Cafe Standards?

CAFE Standards:

The Corporate Average Fuel Economy standards (CAFE) standard enacted in 2014 imposes fuel efficiency and green house gas emission standards on the manufacturers of cars and medium and heavy-duty trucks. These standards get progressively stricter every year, with costly fines imposed for every car or truck model that fails to meet them. Cars must improve performance by 37% and trucks by 23% every year.

Generally speaking, automakers have been beating the CAFE standard every year. It’s in the interests of the manufacturers to build lighter and more efficient vehicles while maintaining high safety standards. How do the manufacturers manage to do that? The goals are achieved by improving engine and transmission technologies, body aerodynamics that reduce air resistance at high speeds, tires with lower rolling resistance, and very importantly parts that reduce weight.

Weight reducing manufacturing technologies:

  • Hydroforming technologies can shape aluminum, brass, steel and stainless steel into complex, hollow forms which are lightweight and structurally stiff and strong.
  • Hydroformed parts eliminate most of the heavy welding required in conventional parts assembly.
  • Using hydroforming technology in manufacture produces structures with fewer separate parts and fewer heavy welds and joints.
  • Hydroforming uses dies capable of high precision, able to meet the exacting tolerances of aircraft parts.
  • Replacing sheet metal bending and joining with hydroforming eliminates multiple welds and draw marks produced by the traditional method of pressing a male and female die together.

A typical example of the benefit of hydroforming is cited by Professor Muammer Ko, of the Virginia Commonwealth University.  Prof. Koe talked about an aluminum radiator support for a passenger car.

  • The stamped manufacture process requires 17 unique parts weighing a total of 16.5 kilograms.
  • The hydroformed part is comprised of 10 parts and weighs 11.5 kilograms (a 30% weight savings).

The hydroforming process can produce structurally stiff and stable parts out of materials that are lighter in weight but able to replace stamped parts made with heavier materials.

  • When an aluminum part replaces a steel or cast-iron part, it means a weight reduction of 40% to 60%.
  • Warm hydroforming greatly increases the formability of lightweight materials like aluminum and magnesium, greatly increasing the possible range of hydroformed parts manufacturing.

Although stamping and welding have not gone away, increasing proportions of the automotive production has gone to hydroforming.

American Hydroformers engineers and manufactures tube hydroformed parts for the automotive industry out of Midwestern facility. Please contact us for more information.