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Hydroforming is a cost-effective way of shaping malleable metals such as aluminum into lightweight, structurally stiff and strong pieces. This technique is particularly popular with the high-end sports car industry and is also frequently employed in the shaping of aluminium tubes for bicyle frames. To hydroform aluminum into a vehicle's frame rail, a hollow tube of aluminum is placed inside a negative mold that is shaped how the end result should look. High pressure hydraulic pistons then pressurize the inside of the aluminum to thousands of PSI which causes it to expand until it matches the mold. The hydroformed aluminum is then removed from the negative mold and used in the application.
Technically the forming of tubing by this process is hydramolding, based on the 1950's patent by Milton Garvin of the Schaible Company. It was originally used in producing kitchen spouts. This was done because in addition to the strengthening of the metal as detailed above, Hydramolding also produced less "grainy" parts, allowing for easier metal finishing.
Popular vehicles that utilize this techology:
- 2004+ Ford F-150
- 5th generation Chevrolet Corvette (1995-2004)
- 6th generation Chevrolet Corvette (2005-Current)
- Modern Aston Martin vehicles such as the DB7
- Pontiac concept car Solstice
- 2006 Saturn Sky
- 2006 Subaru Impreza
- 2003+ Ford Crown Victoria, Mercury Grand Marquis, and Lincoln Town Car
- Harley Davidson V-Rod motorcycle
- Mountain Cycle San Andreas Mountain Bike
Controversy
Hydroforming is also used in the construction of non-transportation items. Notable among these is a patent controversy in the use of the process to produce steel drums. A pair of US inventors applied for a patent using this process, but it is accepted that Trinidad and Tobago Instruments Ltd. had used this process previously in the production of steel drums.
Links
//www.trinicenter.com/Terryj/2002/Apr/162002.htm Pan Shocker:Americans patent pan plan
"Hydroforming"