Hydroforming Rail

All-aluminum spaceframe engineered by Dana Corporation.
Hydroforing is considered as one of potential technologies to reduce weight. Basically,
there are 2 main hydroforming methods : Tube Hydroforming and Sheet Hydroforming.

A pre-bended tube is placed in a tool set in a press which applied the closing force. At the 

ends of the tube 2 cylinders are placed that can apply axial feeding. The tube will be filled with

fluid and the tube will be formed under pressure.

Because the availability of reliable Finite Element Models (FEM) that eliminate the expensive

trial and error process in the development of tools an component. 

Tube Hydroforming. Chevrolet Corvette.


The advantages of hydroforming vis-à-vis the stamped-sheet metal/spot-welded alternatives are structural continuity, reduced welding and joining, part consolidation, tooling investment reduction, a reduction of engineered trim offal, cost reduction, and potential mass reduction. These advantages ultimately contribute to vehicle integrity, ride and handling, and economy.

Hydroforming enables manufacturing of closed sections with non-uniform cross-sectional
area along the length by using a circular tube as the input material. While conventional stamped
and welded closed sections need a flange area to facilitate welding, hydrofromed closed
sections enables weight saving by avoiding the flange area.

The water pressure helps the aluminium tube fit with the die precisely.

The approximately 90 aluminum extrusions, castings, and stampings that comprise the spaceframe represent a 30 percent reduction in mass from the original all-steel design of the preceding model, as well as a reduction in the overall number of parts used.

Reference :

Modern Marvels : Aluminum.
Tube Hydroforming in Automotive Applications