Repair 7

Sheet Metal Working Automotive Technique

Many structural components in automobiles are made from thin, sheet metal, supported by thicker pieces of metal, known as beams. Steel is still largely the metal of choice for automobiles, but other metals, such as zinc or nickel, may be added.

Stamping

Sheet steel automotive parts are typically stamped from rolled metal, using a stamping press and one or more cutting devices, known as a die. Parts such as hub caps and fenders are produced in this way.

Superplastic Forming

Traditionally, aluminum sheet metal parts for automotive use were formed by a hot blow forming process, known as superplastic forming. Superplastic forming is performed under controlled conditions, with regard to temperature and strain, and increases the ease with which aluminum alloys can be shaped.

Quick Plastic Forming

Superplastic forming is expensive -- up to three times more expensive than regular blow forming -- so the Department of Energy and General Motors developed a variation of the process, known as quick plastic forming. The process is faster and more cost-effective than superplastic forming.