Complex thin components are essential parts of rockets, aircraft, cars, and high-speed trains. Under the increasing demand for lightweight and reliable new transportation vehicles, conventional welded structures are unsatisfactory and their replacement with integrated vehicles is urgently called for. To overcome great challenges in the manufacturing of integrated thin components, a new fluid pressure forming technology has been developed for tubes, sheets, shells, and light alloy metals. A method to adjust the stress states in deforming regions by controlling the fluid medium pressure was proposed in order to solve severe defects such as wrinkling, splitting, and local thinning. A series of innovative processes based on this method have been successfully developed, including lower pressure hydroforming of tubular components, double-sided pressure hydroforming of sheet components, die-less hydroforming of ellipsoidal shells, and hot medium pressure forming of hard-to-deform materials. The new fluid pressure forming technology contributes to breaking through the limitations of conventional processes and promoting the advancement of manufacturing technology for new transportation vehicles.
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