Hydroforming
of Lightweight Components from Aluminum and Magnesium Sheet and Tube –
Investigation of Formability at Room and Elevated Temperatures--Applied
Engineering Solutions, LLC, 5537
Corey Swirl Drive,
Dublin,
OH
Mr.
David E. Guza, Principal Investigator, guzade@aol.com
Mr.
David E. Guza, Business Official, guzade@aol.com
DOE
Grant No. DE-FG02-02ER86141
Amount:
$99,924
Columbus,
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 magnesium and aluminum alloys in tube and sheet components has
been restricted due to their limited formability at room temperatures in
conventional metal stamping processes. The
use of novel fabrication methods can open up a wide range of design
possibilities by circumventing these traditional materials problems.
This project will develop a deeper understanding of the formability of
magnesium and aluminum alloys to ultimately exploit their lightweight
characteristics and ultimate cost savings. Phase
I will employ the tube and sheet hydroforming process to define formability and
process parameters. The formability
of selected magnesium and aluminum alloys will be studied at room and elevated
temperatures using novel hydroforming fabrication methods.
The results of this Phase I effort will establish a deeper understanding
of the process parameters necessary to form these alloys into useful shapes and
provide a solid foundation upon which to develop a practical rapid-production
hydroforming industrial machine design with optimized processing parameter
definitions.
Commercial
Applications and Other Benefits
as described by the awardee: A wide
application range should exist for hydroforming magnesium and aluminum alloys in
the automotive, aerospace and marine industries.
Examples include complexly shaped exhaust manifolds, auto body frame
components, lightweight door panels, trays, torque tubes, and fluid transport
conduits, to name just a few. Benefits
include not only significant energy cost savings due to the use of lightweight
alloys in vehicular design but also more engineering design flexibility to
produce more efficient and safer consumer products.