In the proposed hydro ironing method, through an innovative arrangement of loads and using a novel configuration for the die components, the thickness reduction in one stage of ironing is almost equal to twice the common approaches.

In the proposed hydro ironing method, through an innovative arrangement of loads and using a novel configuration for the die components, the thickness reduction in one stage of ironing is almost equal to twice the common approaches.

A method of producing an integrated monolithic aluminum structure, the method includes the steps of: (a) providing an aluminum alloy plate with a predetermined thickness of at least 38.1 mm, wherein the aluminum alloy plate is a 7xxx-series alloy provided in an F-temper or an O-temper; (b) optionally pre-machining of the aluminum alloy plate to an intermediate machined structure; (c) high-energy hydroforming of the plate or optional intermediate machined structure against a forming surface of a rigid die having a contour in accordance with a desired curvature of the integrated monolithic aluminum structure, the high-energy hydroforming causing the plate or the intermediate machined structure to conform to the contour of the forming surface to at least one of a uniaxial curvature and a biaxial curvature; (d) solution heat-treating and cooling of the high-energy hydroformed structure; (e) machining and (f) ageing of the final integrated monolithic aluminum structure.

A method of producing an integrated monolithic aluminum structure, the method includes the steps of: (a) providing an aluminum alloy plate with a predetermined thickness of at least 38.1 mm, wherein the aluminum alloy plate is a 7xxx-series alloy provided in an F-temper or an O-temper; (b) optionally pre-machining of the aluminum alloy plate to an intermediate machined structure; (c) high-energy hydroforming of the plate or optional intermediate machined structure against a forming surface of a rigid die having a contour in accordance with a desired curvature of the integrated monolithic aluminum structure, the high-energy hydroforming causing the plate or the intermediate machined structure to conform to the contour of the forming surface to at least one of a uniaxial curvature and a biaxial curvature; (d) solution heat-treating and cooling of the high-energy hydroformed structure; (e) machining and (f) ageing of the final integrated monolithic aluminum structure.

A method of hot forming a pair of hollow components. The method involves heating a die stack comprising a first die, an intermediate die and a second die, in which the first die and the intermediate die form a first die set, and the intermediate die and the second die form a second die set. The die stack is opened and loaded with a first component preform in the first space and a second component preform in the second space. Once loaded, the die stack is closed and a pressurised fluid is then provided via a first conduit to an internal cavity of the first component preform, while a pressurised fluid is also provided via a second conduit to an internal cavity of the second component preform. The die stack is opened and the first component and the second component removed from the respective first space and the second space.

A method of hot forming a pair of hollow components. The method involves heating a die stack comprising a first die, an intermediate die and a second die, in which the first die and the intermediate die form a first die set, and the intermediate die and the second die form a second die set. The die stack is opened and loaded with a first component preform in the first space and a second component preform in the second space. Once loaded, the die stack is closed and a pressurised fluid is then provided via a first conduit to an internal cavity of the first component preform, while a pressurised fluid is also provided via a second conduit to an internal cavity of the second component preform. The die stack is opened and the first component and the second component removed from the respective first space and the second space.