A structural component for an automotive vehicle formed from a single-piece of steel material and having a closed, complex cross-section with increased strength, for example a strength of greater than 650 MPa, and thus improved performance, is provided. The structural component typically has an elongation of greater than 5%. The structural component is formed by expanding a boron-containing steel material, for example heating or hydroforming a tube of the steel material. The boron-containing steel material expands by least 2% during the forming process and thus achieves the closed, complex cross-section, while also achieving the high strength. In addition, the structural component can be formed with zones of varying thickness, strength, hardness, elongation, and/or other varying properties to achieve the desired performance.

A structural component for an automotive vehicle formed from a single-piece of steel material and having a closed, complex cross-section with increased strength, for example a strength of greater than 650 MPa, and thus improved performance, is provided. The structural component typically has an elongation of greater than 5%. The structural component is formed by expanding a boron-containing steel material, for example heating or hydroforming a tube of the steel material. The boron-containing steel material expands by least 2% during the forming process and thus achieves the closed, complex cross-section, while also achieving the high strength. In addition, the structural component can be formed with zones of varying thickness, strength, hardness, elongation, and/or other varying properties to achieve the desired performance.

Provided herein is a high-speed blow forming process for shaping aluminum containers using 3xxx can body stock alloys with high recycled content, as well as articles made by that process. A process for shaping aluminum containers as described herein includes the sequential steps of blanking out a disk from a sheet of a 3xxx series aluminum alloy; forming a bottle preform by drawing redrawing, ironing and doming the disk, placing the preform into a mold cavity, applying an axial load to the preform; and injecting an inert gas into the interior of the preform with sufficient pressure until the preform expands to fill the mold cavity.

Provided herein is a high-speed blow forming process for shaping aluminum containers using 3xxx can body stock alloys with high recycled content, as well as articles made by that process. A process for shaping aluminum containers as described herein includes the sequential steps of blanking out a disk from a sheet of a 3xxx series aluminum alloy; forming a bottle preform by drawing redrawing, ironing and doming the disk, placing the preform into a mold cavity, applying an axial load to the preform; and injecting an inert gas into the interior of the preform with sufficient pressure until the preform expands to fill the mold cavity.

A hot forming by gas and direct quenching method and apparatus are disclosed. One method of using the system includes a heating step, a forming step, and a direct quenching step. This method increases the quenching speed and allows common steels with high critical cooling rate to be hot formed and quenched. This method reduces or eliminates the need for a furnace and/or the coating of the workpiece prior to the forming, as well as the removal of the coating after the forming. Furthermore, by using a hot gas containing carbon or nitrogen, the workpiece may be case hardened after the heating, forming and quenching steps.

A hot forming by gas and direct quenching method and apparatus are disclosed. One method of using the system includes a heating step, a forming step, and a direct quenching step. This method increases the quenching speed and allows common steels with high critical cooling rate to be hot formed and quenched. This method reduces or eliminates the need for a furnace and/or the coating of the workpiece prior to the forming, as well as the removal of the coating after the forming. Furthermore, by using a hot gas containing carbon or nitrogen, the workpiece may be case hardened after the heating, forming and quenching steps.

A method of producing an integrated monolithic aluminum structure, comprising: providing an aluminum alloy plate with a thickness of at least 38.1 mm, wherein the plate is a 2xxx-series alloy in a T3-temper and has a composition comprising, in wt. %: Cu 3.8-4.5, Mn 0.3-0.8, Mg 1.1-1.6, Si up to 0.15, Fe up to 0.20, Cr up to 0.10, Zn up to 0.25, Ti up to 0.15, Ag up to 0.10, balance aluminum; optionally pre-machining the plate to an intermediate machined structure; high-energy hydroforming the plate or intermediate structure against a rigid die forming surface having a desired curvature contour of the integrated monolithic aluminum structure, causing the plate or the intermediate structure to conform to the forming surface contour; machining or mechanical milling the high-energy formed structure to a near-final or final machined integrated monolithic aluminum structure; ageing the final integrated monolithic aluminum structure to a desired temper.

A method for forming a multilayer structure from a precursor panel having an edge, the method including steps of connecting an attachment member to the precursor panel such that an edge of the attachment member is in alignment with the edge of the precursor panel and applying heat and gas pressure to expand the precursor panel.

A method for forming a multilayer structure from a precursor panel having an edge, the method including steps of connecting an attachment member to the precursor panel such that an edge of the attachment member is in alignment with the edge of the precursor panel and applying heat and gas pressure to expand the precursor panel.

A method of making a metal reinforcing member that is to be mounted on a leading edge or a trailing edge of a composite blade of a turbine engine, the method including: shaping two metal sheets, positioning them on either side of a core including at least one recess that is to form a mold for a spacer for positioning the reinforcing member, assembling them together under a vacuum, conforming them against the core by hot isostatic compression, and cutting them to separate the reinforcing member and release the core.