Hot metal gas formed roof rail and method of manufacture thereof

1. A method of manufacturing a formed aluminum component, the method comprising:

providing a hollow aluminum profile of a 6000 or 7000 series aluminum alloy, the hollow aluminum profile having a predetermined length and comprising an outer wall having a predetermined thickness;

placing the hollow aluminum profile in a cavity of a bending tool and press bending the hollow aluminum profile using the bending tool at a tool temperature more than or equal to 350° C. and less than or equal to 470° C.; and

placing the hollow aluminum profile in a cavity of a forming tool and subjecting an interior of the hollow aluminum profile to elevated gas pressure at a tool temperature more than or equal to 350° C. and less than or equal to 470° C., until a section of the hollow aluminum profile is distended such that the outer wall of the hollow aluminum profile abuts the forming tool, thereby providing the formed aluminum component, and wherein placing the hollow aluminum profile in the cavity of the forming tool and subjecting the interior of the hollow aluminum profile to elevated gas pressure is performed for a duration of between 2 seconds and 240 seconds, so that an average grain diameter of the formed aluminum component does not exceed 250 μm.

2. A method according to claim 1 , wherein placing the hollow aluminum profile in the cavity of the forming tool and subjecting the interior of the hollow aluminum profile to elevated gas pressure is performed at a tool temperature more than or equal to 370° C. and less than or equal to 460° C.

3. A method according to claim 1 , wherein placing the hollow aluminum profile in the cavity of the forming tool and subjecting the interior of the hollow aluminum profile to elevated gas pressure is performed at a pressure more than or equal to 50 Bar and less than or equal to 250 Bar.

4. A method according to claim 1 , wherein placing the hollow aluminum profile in the cavity of the forming tool and subjecting the interior of the hollow aluminum profile to elevated gas pressure is performed at a tool temperature more than or equal to 350° C. and less than or equal to 470° C. for a duration of more than or equal to 60 seconds and less than 240 seconds, at a pressure more than or equal to 50 Bar to less than or equal to 250 Bar.

5. A method according to claim 1 , wherein placing the hollow aluminum profile in the cavity of the forming tool and subjecting the interior of the hollow aluminum profile to elevated gas pressure is performed at a tool temperature of more than 450° C. but less than or equal to 470° C., and for a duration of less than 60 seconds and more than 2 seconds, at a pressure of 50 Bar to 250 Bar.

6. A method according to claim 1 , wherein the hollow aluminum profile has a substantially circular or substantially oval cross-section and the predetermined outer wall thickness is 1 mm to 10 mm.

7. A method according claim 1 , wherein the bending tool and the forming tool are integrated into a single tool having separate cavities for bending and forming.

8. A method according to claim 1 , further comprising rotating the hollow aluminum profile 90° around a lengthwise axis after being place in the cavity of the bending tool and before being placed in the cavity of the forming tool.

9. A method according to claim 8 , wherein the bending tool and forming tool are integrated into a single tool having a single cavity for bending and forming.

10. A method according to claim 1 , further comprising preheating the hollow aluminum profile prior to placing the hollow aluminum profile in the cavity of the bending tool for a duration of more than or equal to 10 seconds and less than or equal to 10 minutes.

11. A method according to claim 1 , further comprising providing the hollow aluminum profile with a lubricant prior to placing the hollow aluminum profile in the cavity of the bending tool.

12. A method according to claim 11 , wherein the lubricant is an aqueous graphite lubricant.

13. A method according to claim 1 , further comprising forcedly cooling the formed aluminum component.

14. A method according to claim 13 , wherein forcedly cooling the formed aluminum component includes using air as a cooling medium.

15. A method according to claim 1 , further comprising etching the formed aluminum component for a duration of more than or equal to 1 minute and less than or equal to 20 minutes using an etchant solution.

16. A method according to claim 1 , further comprising heat treating the formed aluminum component at a temperature of more than or equal to 170° C. to less than or equal to 200° C. for a duration of more than or equal to 5 hours and less than or equal to 15 hours.

17. A method of manufacturing a formed aluminum component, the method comprising:

providing a hollow profile of aluminum or aluminum alloy, the hollow profile having a predetermined length and comprising an outer wall having a predetermined thickness;

placing the hollow profile in a cavity of a bending tool and press bending the hollow profile using the bending tool at a tool temperature more than or equal to 350° C. and less than or equal to 470° C.; and

placing the hollow profile in a cavity of a forming tool and subjecting an interior of the hollow profile to elevated gas pressure at a tool temperature more than or equal to 350° C. and less than or equal to 470° C., until a section of the hollow profile is distended such that the outer wall of the hollow profile abuts the forming tool, thereby providing a formed aluminum component,

wherein the bending tool and the forming tool are integrated into a single tool having separate cavities for bending and forming.