Tubular Blank

Tubular Blanks are more expensive than standard tubes, although they offer greater potential for the final hydroformed solution.

Standard tubes are manufactured in a continuous process starting with a slit coil and delivering a resistance welded continuous tube which is sheared to an approximate length. In contrast, Tubular Blanks are manufactured from pre blanked sheet which is press formed into a tube and then laser welded. The cycle time for manufacturing a Tubular Blank is therefore greater than that for manufacturing an equivalent length of standard ERW tube.

The Tubular Blank enables tubes to be manufactured with significantly more ductility than tubes manufactured using a conventional process. The tube may also be tailored using different gauges and/or grades, either along the length or circumferentially. Conical tubes, as well as rounds, may be manufactured using this process. Tubular Blanks can also be manufactured in significantly higher diameter to thickness ratios than normal tube and with greater precision, both in diameter and length. The tubular blank is particularly suited to more demanding applications or where parts consolidation may be achieved by leveraging the benefits associated with tailored materials.

The heat affected zone for a laser welded tube is significantly smaller than that of a resistance welded tube, protecting the material properties in this area. This can offer significant advantages in formability, particularly in more demanding applications.

No. The tubular blank can be made as a conical tube and may have non-circular profiles. The only restriction is that the finished tube shape must be developable back to a flat sheet.

In demanding applications, on the limit of feasibility for standard tubes, Tubular Blanks can offer cost savings by the reduction in scrap and wasted process costs.

Significant mass savings may be achieved for equivalent performance by using larger, thinner sections. The Tubular Blank can deliver tubes with significantly higher diameter to thickness ratios than standard tubes, making these tubes the product of choice when seeking high performance weight saving.

The Conical Tubular Blank offers opportunities for hydroforming in areas which are not accessible to traditional cylindrical tubes. Structural and safety critical applications, in areas such as the B-Pillar, may yield significant weight savings without compromising performance.

In demanding applications, on the limit of feasibility for standard tubes, Tubular Blanks can offer cost savings by the reduction in scrap and wasted process costs.
Significant mass savings may be achieved for equivalent performance by using larger, thinner sections. The Tubular Blank can deliver tubes with significantly higher diameter to thickness ratios than standard tubes, making these tubes the product of choice when seeking high performance weight saving.

The Conical Tubular Blank offers opportunities for hydroforming in areas which are not accessible to traditional cylindrical tubes. Structural and safety critical applications, in areas such as the B-Pillar, may yield significant weight savings without compromising performance.

For areas where the Tubular Blank does not offer a benefit, Hyfo can supply a wide range of standard ERW tubes.

For areas where the Tubular Blank does not offer a benefit, Hyfo can supply a wide range of standard ERW tubes.

The Tubular Blank is more expensive than standard tubes so a rigorous economic justification must be carried out prior to committing to using Tubular Blanks. If the product can be manufactured from standard tubing, Hyfo would not advise using a Tubular Blank, unless other benefits would be achieved. Hyfo will work with their customers to enable the optimum choice of tube to be made.

• Diameter to thickness ratios of up to 200
• Thicknesses between 0.5 and 4mm
• Diameter range of 30 to 250mm
• Taper (for conical tubes) of 30% of diameter per metre length
• Tolerance for cut to length of +/- 1mm
• Tolerance on diameter of +/- .5mm

There are examples of the Tubular Blank in current high volume production. In addition we are currently working with many OEM and Tier 1 suppliers providing Tubular Blanks for prototyping activities.