Archive for the Metal Fabrication Category

Hydroformed Components: New Metals on the Market

Hydroformed Components: New Metals on the Market

There has been recent news about hydroforming bringing titanium to the masses. Until recently, it was difficult to use titanium on a commercial scale because of the cost as compared to the more affordable but weaker alternatives such as stainless steel. Hydroforming has pioneered cost saving methods to take advantage of titanium and its benefits.

But titanium isn’t the only alloy that has advantages for hydroformed components. Kinesium is a relatively new alloy that holds great potential by using the favorable aspects of both titanium and aluminum:

  • Kinesium is 25% stronger than 7005 series aluminum
  • The greater concentration of titanium allows for improved hardness and tensile strength
  • Kinesium is lightweight, partially because of the aluminum, but also because the greater strength allows for a thinner wall thickness in tubing
  • Kinesium is very affordable as an alloy because of its aluminum content

The company who created Kinesium, Kinesis, was specifically testing for an alloy that could make better bicycle frames. The innovation and opportunities provided by hydroforming have allowed this company to expand the possibilities of this alloy. The use of hydroforming also allowed Kinesis to create a shape that can withstand stresses experience by high performance bikes:

 

“Our Hydroformed tube shapes are designed to increase the effective strength of the frame by distributing stresses over a broad section of the tubes, instead of allowing them to be concentrated in small areas… The Hydroformed gussets and multi-section tube shapes are achieved with virtually no added weight.” (Kinesis UK)

 

For cyclists, hydroformed components made of Kinesium mean cost-effective and higher quality bicycle frames. For the industry, hydroformed kinesium offers a lightweight yet incredibly strong alternative for parts with complex geometries that can stand up to more stress than traditional metals and traditional metal stamping. The future is bright for other commercial uses, from the automotive to more personal uses around the household.

Hydroforming is taking the lead on innovative uses for new alloys. To learn more about hydroforming and about how to exercise its capabilities, please contact us.

Understanding Metal Stamping and Its Many Uses

Understanding Metal Stamping and Its Many Uses

Metal stamping is a process which includes the stamping or pressing of sheet metal into different forms. Some of the different types of metal stamping include punching, deep drawing, pressing, embossing, bending, flanging, and coining to name a few. The most common medium for metal stamping is sheet metal but it can be performed on other types of materials such as polystyrene. The process of stamping can produce an specified object repeatedly normally within a few steps which makes stamping economically favorable.

In many cases the initial process of stamping involves a simulation process. A metal working firm can take specs, measurements, and blueprints in order to perform a test run on the product being stamped. Once the test pieces are made, they can be tested for durability. These tests can include the analysis of possible defects such as wrinkling, splits, and thinning. This simulation saves the hiring manufacturing company time and money since the analysis performed produces a minute batch of product for testing.

Because of its versatility, metal stamping can benefit a wide range of industries. The automotive industry uses metal stamping often in order to produce a large amount of parts with minimal man power and resources. The marine industry, medical industry, construction industry, and aerospace technology industry all use metal stamping to manufacture their parts and products.

American Hydroformers has been a metal working industry leader since 2003. They have produced exceptional quality products for a variety of industries; coupling their expert metal forming capabilities with a strong focus on customer satisfaction. American Hydroformers uses cutting-edge technology in order to ensure your final product exceeds your expectations.

While American Hydroformers technology revolves around hydroforming, we may have an alternative application different from stamping that could be economically more feasible.

Please, contact us for more information.

Hydroforming Advantages for Automotive

Hydroforming Advantages for Automotive

Hydroforming metal is one of the most cost effective ways of creating asymmetrical parts for the automotive industry. Many parts used on cars today have irregular shapes making traditional methods of manufacturing more cumbersome and expensive. The strength and weight of hydroformed parts also lends to better produced products which are easier to work while maintaining an overall better structural integrity. Here are some other hydroforming advantages that make it one of the best choices for fabricating parts for the automotive industry:

  • Reduced tooling costs: When manufacturing parts the traditional way, jigs and other forms must be manufactured before the process of fabrication begins. If a company only needs a small quantity of the manufactured parts, the increase in cost for tooling greatly affects the bottom line.
  • Increased quality and precision: Hydroforming uses a technique which employs a press, pressurized fluid, and a punch. This process is not only quicker than traditional types of fabrication, it also ensures greater accuracy because their are less steps in the process of hydroforming than traditional manufacturing.
  • Deep-drawing with less stretch: Hydroforming uses less friction in the manufacturing process. Deep draws can be performed with less material stretch. This means the product will have a better integrity as well as less blemishing; in turn requiring less finishing work.
  • The versatility of hydroforming: Steel, copper, brass, aluminum, alloys, etc can be manufactured into parts using the hydroform process. When dealing with these types of materials, many additional efforts must be put into place with traditional fabrication processes as to not damage or weaken the material.

In the automotive industry material strength is essential for safety. The race industry has especially seen benefits from the light weight and structurally sound parts developed as a result of hydroforming. As hybrid vehicle become more and more popular, hydroforming has played an integral part in keeping cars efficient through bettering the manufacturing process. When looking for hydroformed parts you can depend on for strength and lasting durability, please contact  the experts at American Hydroforming.

Advantages of Tubular Hydroforming

Advantages of Tubular Hydroforming

Any item that is built with a metal tube can be made more efficiently and cost effectively with tubular hydroforming. The process was first developed and used in the 1950’s. The disadvantages of pressing and stamping tubes, i.e. weak stress points, unseen defects, and uneven distribution of metal, disappear, leaving a lighter weight but stronger metal tube.

In a nutshell, tubular hydroforming involves pumping hydraulic fluid into shape at high pressure, forcing the metal evenly into all corners of the mold. The metal, aluminum, stainless steel or other metal, flows into the shape of the mold, rather than being stretched over a die, creating a stronger tube than one that has been pressed. The metal can be further heat treated to strengthen it even more.

The advantages of this process include so much more than just light weight and strength. Consider the following.

  • Unique shapes are possible with indents or angles. For instance, one end of the tube could be round, the other oval or a tube could be made with a flattened center section.
  • Even thickness of the metal with no thick or thin spots. This reduces unseen weak spots which can break more easily.
  • Cost effective. Less waste of raw metal or due to damaged finished pieces.
  • Uses less energy to produce. The process is streamlined and robotic, and doesn’t require high temperatures.
  • There is less hazard to employees since the process is done at room temperature.
  • Leaves a smooth surface ready to paint or use as is.

Whatever product using a metal tube you may produce, it is probably possible to produce it better and more inexpensively with tubular hydroforming. The inherent strength of the product produced makes this process ideal for many products and industries, not just automotive and plumbing. It’s also frequently used for bicycles and musical instruments.

Visit our website and view the video of the hydroforming process to easily understand how it works. Then contact us so we can discuss how to help you build a better product through hydroforming. It’s a call you’ll wish you made years ago.