Hydroforming of Lightweight Aluminum and Magnesium Components from Tube-Development and Commercialization of a Novel Elevated Temperature Hydroforming System

Award Information
Agency: Department of Energy
Branch: N/A
Contract: SBAassigned2003DOE1
Agency Tracking Number: SBAassigned2003DOE1
Amount: $0.00
Phase: Phase I
Program: STTR
Awards Year: 2003
Solicitation Year: N/A
Solicitation Topic Code: N/A
Solicitation Number: N/A
Small Business Information
5537 Corey Swirl Drive, Dublin, OH, 43017
DUNS: N/A
HUBZone Owned: N
Woman Owned: N
Socially and Economically Disadvantaged: N
Principal Investigator
 James Hnat
 (610) 489-2255
 jhnat@vortec.org
Business Contact
 David Guza
Phone: (614) 789-9890
Email: guzad@alum.mit.edu
Research Institution
 Lehigh University
 526 Brodhead Avenue
Bethlehem, PA, 18015
 Nonprofit college or university
Abstract
Significant fuel cost savings can be realized in the automotive and aerospace industries by employing lightweight materials in the design and fabrication of vehicular components. To date, the exploitation of lightweight magnesium and aluminum alloys in component fabrication has been restricted due to their limited formability at room temperatures in conventional metal stamping processes. Hydroforming is a relatively new forming process that employs the use of a pressurized fluid to expand tubular blanks into a forming die to create efficiently shaped parts. This project will design, fabricate, and test a practical, elevated-temperature, rapid-production, hydroforming system for the production of complex-shaped, lightweight aluminum and magnesium components. Phase I demonstrated the feasibility of enhancing the formability of selected aluminum and magnesium alloys at elevated temperatures using a novel tube hydroforming apparatus. Phase II will design, fabricate, and test a new prototype elevated-temperature hydroforming system. Computer modeling will be used in conjunction with testing results to optimize process parameters, in order to enhance component formability. The prototype will offer flexible control features to allow for process optimization.

* Information listed above is at the time of submission. *

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