Hydroforming Process

Hydroforming Process Holds Critical Thickness In Manufacturing of Float Parts

Industry:
Manufacturing

Situation:
An Oklahoma manufacturer of stainless steel floats experienced problems with the stamped and spun parts they purchased from another vendor. The pieces were fabricated from 18 gauge stainless steel, which is .048" thick. Both the stamping and spinning processes were thinning the material to .035", causing the floats to explode under pressure. The continued failure of the parts to pass the required ten minute 600 psi test, even after costly tooling changes, was frustrating and expensive. The company was reluctant to expend more on tooling without being certain of a solution.

Solution:
The manufacturer contacted Metalspun and was intrigued to learn that the hydroforming process would maintain the material thickness of the float components, enabling the parts to withstand high pressure and pass the quality tests. However, they were unwilling to spend even more money on tooling only to achieve the same results their other suppliers provided.

Metalspun understood their hesitation and offered to front the initial tooling cost until a superior part was produced that would exceed the required tests. After a few sample exchanges, Metalspun decided to substitute a lighter 19 gauge stainless for the original 18 gauge. In addition, a step was spun on the float halves to add strength and serve as a mating guide for welding. The hydroforming process held the thickness within .002" throughout the run and the thinner material decreased the weight, resulting in even greater cost savings. The new hydroformed and spun floats easily passed the pressurized test. Metalspun's creative approach produced exceptional parts, and repeat orders.

Bottom Line:
Metalspun met the Oklahoma company's challenge. Not only did the floats surpass the pressurized test, but the customer saved money by using a lighter material. Welding time was also reduced by adding the spun step, which mated the parts with ease, and added extra strength to the completed part. This is only one of the many instances that confirm that hydroforming and spinning are a winning combination.