Hydroforming is a process that actually forms complex shapes and makes the extruded profiles suitable enough to perform various roles. Hydroforming permits accurate tailoring of cross section and 3D bending of profiles. Closed section extrusions can be formed with internal water pressure and dies. Hydroforming offers unique possibilities with varying cross sections for structural members and pipes. Local changes, like spigots or holes, can be made also in a hydroforming operation, which results in saving of several processing operations, ultimately leading to a cut in the lead-time.
Advantages Of Hydroforming

• Hydroforming aids the formation of very sharp radius corners, which is shown in the image here:
  
  
  
• With Hydroforming process, cross-sections are modified either on a section of the profile or on the whole profile itself.
  
  
• Complicated details and shapes are created, with high accuracy.
  
  
• Hydroforming operation allows local changes like domes or holes. This helps to save the processing steps, thus leading to shorter lead times.
  
  
• Part consolidation
  
  
• Reduction in weight due to an effective section design along with tailoring of the wall thickness.
  
  
• Enhanced stiffness and structural strength.
  
  
• A low tooling cost due to requirement of fewer parts.
  
  
• Lesser secondary operations.
  
  
• Tight tolerances
  
  
• Low springback
  
  
• Reduction in scrap
  
  

Working of the Hydroforming Process
The hydroforming process commences with placing of extruded aluminium tube shaped in three dimensions in a hydroforming press. Water is then filled subsequently and high pressure is applied. The material is forced to expand by the pressure and consequently it is shaped according to the outer contours of the tool. The process is explained through these images: