An Experimental Study on the Groove Design for Joints Produced by Hydraulic Expansion Considering Axial or Torque Load

Marré, M.1, a; Rautenberg, J.2, b; Tekkaya, A. E.1, c; Zabel, A.2, d; Biermann, D.2, e; Wojciechowski, J.3; Przybylski, W.3

Institut für Umformtechnik und Leichtbau, Technische Universität Dortmund, Baroper Str. 301, 44227 Dortmund
Institut für Spanende Fertigung, Technische Universität Dortmund, Baroper Str. 303, 44227 Dortmund
Faculty of Mechanical Engineering, Gdansk University of Technology, Polen

a); b); c); d); e)


This article presents research work on the influence of the design characteristics of the joint partner elements and especially of grooving and pocketing on the tensile and torsional strength of tubular joints produced by hydraulic expansion when tubes are made of aluminum EN AW-6060. In general, joining of tubular elements can be performed by different methods, but internal expansion presents an interesting alternative to other methods like welding and mechanical forming processes. Commonly, hydraulic expansion is used for the manufacturing of heat exchangers. As a result, time effective and resistant joints must be produced in particular when applying hydraulic expansion in the manufacturing of lightweight structures.


EN AW-6060, Hydraulic expansion, Joining of tubes, Lightweight structures


Materials and Manufacturing Processes, 27 (2012) 5, S. 545-555