Exemplary vehicle structures include a frame component that provides greater strength and/or other desired properties to a vehicle structure. The frame component includes a first wall (6) and a second wall (7). The first and second walls each comprise at least one metal sheet. The first and second walls bound a sealed interior gap (28). Pressurized fluid is introduced into the sealed interior gap through at least one of the walls via a fluid connector (8). In some arrangements the gap includes a hermetically sealed pocket (110) that is bounded by a pocket wall (36). The pressurized fluid is delivered into the pocket interior area that is bounded by the pocket wall. The fluid delivered to the sealed interior gap and/or the pocket interior area may be operative to cause controlled permanent deformation thereof to produce desired wall configurations which have increased strength. The fluid housed within the sealed interior gap may provide increased strength or other desired properties. Vehicle structures such as vehicle side frames, vehicle floor members and vehicle frame longitudinal members may each include one or more of the frame components integrated in the vehicle structure.

A hybrid fluid-flow assembly having a base fitting that has been formed by axial load bulge forming from a sheet of metal, and a custom fitting that has been machined from a shaped-memory alloy. At least one connection port of the custom fitting is connected to at least one connection port of the base fitting by an interference fit. The interference fit is formed by cooling the custom fitting to a temperature below its transition temperature, deforming the custom fitting so that the diameter of its connection port is slightly larger than the connection port on the base fitting, installing the connection port of the custom fitting on the connection port of the base fitting, and allowing the custom fitting to warm to room temperature. The shaped-memory alloy swages and coins the outer surface of the base fitting at the interface of the ports, thereby forming a compressive, interference fit.

The controller controls the gas supply of the gas supply unit so as to maintain a pressure in a metal pipe material at a first pressure when a gas is supplied into the metal pipe material which is formed into a pipe portion in a main cavity portion in a state where an upper die and a lower die are joined to each other. It is possible to prevent pressure drop in the pipe portion caused by cooling of the pipe portion due to a contact between the dies, and the pipe portion. Thus, it is possible to suppress a decrease in a force for pressing the pipe portion against the dies. It is possible to suppress a decrease in adhesion between the pipe portion and the dies when the metal pipe is formed, and it is possible to suppress occurrence of variations in hardenability in the pipe portion.

The controller controls the gas supply of the gas supply unit so as to maintain a pressure in a metal pipe material at a first pressure when a gas is supplied into the metal pipe material which is formed into a pipe portion in a main cavity portion in a state where an upper die and a lower die are joined to each other. It is possible to prevent pressure drop in the pipe portion caused by cooling of the pipe portion due to a contact between the dies, and the pipe portion. Thus, it is possible to suppress a decrease in a force for pressing the pipe portion against the dies. It is possible to suppress a decrease in adhesion between the pipe portion and the dies when the metal pipe is formed, and it is possible to suppress occurrence of variations in hardenability in the pipe portion.

The controller controls the gas supply of the gas supply unit so as to maintain a pressure in a metal pipe material at a first pressure when a gas is supplied into the metal pipe material which is formed into a pipe portion in a main cavity portion in a state where an upper die and a lower die are joined to each other. It is possible to prevent pressure drop in the pipe portion caused by cooling of the pipe portion due to a contact between the dies, and the pipe portion. Thus, it is possible to suppress a decrease in a force for pressing the pipe portion against the dies. It is possible to suppress a decrease in adhesion between the pipe portion and the dies when the metal pipe is formed, and it is possible to suppress occurrence of variations in hardenability in the pipe portion.

The controller controls the gas supply of the gas supply unit so as to maintain a pressure in a metal pipe material at a first pressure when a gas is supplied into the metal pipe material which is formed into a pipe portion in a main cavity portion in a state where an upper die and a lower die are joined to each other. It is possible to prevent pressure drop in the pipe portion caused by cooling of the pipe portion due to a contact between the dies, and the pipe portion. Thus, it is possible to suppress a decrease in a force for pressing the pipe portion against the dies. It is possible to suppress a decrease in adhesion between the pipe portion and the dies when the metal pipe is formed, and it is possible to suppress occurrence of variations in hardenability in the pipe portion.

A hybrid fluid-flow assembly having a base fitting that has been formed by axial load bulge forming from a sheet of metal, and a custom fitting that has been machined from a shaped-memory alloy. The input port of the custom fitting is connected to the output port of the base fitting by an interference fit. The interference fit may be formed by cooling the custom fitting to a temperature below its transition temperature, deforming the custom fitting so that the diameter of an inlet port is slightly larger than an output port on the base fitting, installing the input port of the custom fitting on the output port of the base fitting, and allowing the custom fitting to warm to room temperature. The shaped-memory alloy swages and coins the outer surface of the base fitting at the interface of the ports, thereby forming a compressive, interference fit.

A method for obtaining a camshaft for an internal-combustion engine having a structure made of a single piece includes obtaining the camshaft by starting from a metal tubular element. The cams are obtained by expanding the tubular element within a die using high-pressure fluid. The tubular element can have an enlarged thickness in portions that are to form the cams. Forming with high-pressure fluid can be obtained using gas or liquid (for example, water or oil) at high pressure, at room temperature or at a higher temperature. The piece obtained is subjected to thermal treatment and to a grinding operation.

A method for obtaining a camshaft for an internal-combustion engine having a structure made of a single piece includes obtaining the camshaft by starting from a metal tubular element. The cams are obtained by expanding the tubular element within a die using high-pressure fluid. The tubular element can have an enlarged thickness in portions that are to form the cams. Forming with high-pressure fluid can be obtained using gas or liquid (for example, water or oil) at high pressure, at room temperature or at a higher temperature. The piece obtained is subjected to thermal treatment and to a grinding operation.

A device for a plumbing installation, the device, for example, may be a valve, such as valve (1), or a fluid flow meter (6), and has a casing (10) that is hydraulically formed from metal tubing so as to have a wall surrounding a void interior. The casing (10) is provided with one or more formations, such as shoulders (64) and (65) and at least one inlet opening (14) and at least one outlet opening (18). A cartridge (12) is at least partly located in the void interior of the casing (10). The cartridge (12) has at least two openings, being a first opening (20) and a second opening (22). Seals (46), (48) and (50) are provided between the casing (10) and the cartridge (12). The cartridge (12) is accommodated in the casing (10) by the one or more formations of the casing (10). The cartridge (12) is provided with the operational components of the device (1). The inlet opening (14) of the casing (10) and the first opening (20) of the cartridge (12) are in fluid communication. Similarly, the second opening (22), of the cartridge (12) and the outlet opening (18) of the casing (10) are in fluid communication. A fluid flow path is thereby created through the device (1) from the inlet opening (14) of the casing (10), through the cartridge (12), to the outlet opening (18) of the casing (10).