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In recent years a steadily growing interest in applying lightweight construction concepts could be observed. This development is accompanied by an increasing demand for innovative forming strategies suitable for extending the forming limits of the typical lightweight materials. Deep drawing combined with an integrated electromagnetic calibration step is an example of such a technology. The feasibility and potential of this process combination is analyzed on the basis of a demonstrator part from the automotive industry. Thereby, aspects related to the practicability of the electromagnetic forming process itself are regarded as well as points related to the deep drawn preform. The concept of a 3D-coil insert, integrated into a deep drawing punch in order to realize the calibration in the deep drawing process, is introduced and based on the experimental results, conclusions regarding the applicability of the process combination are drawn.

Joining of lightweight frame structures in small quantities is subject to specific conditions, which are exemplarily determined for joining by forming processes. Experimental investigations have been carried out to evaluate both feasibility and capability of joining by forming processes. Joining has been accomplished by compressing or expanding cylindrical profiles using rigid tools for rolling-in processes, fluid active medium for hydro-forming as well as active energy for electromagnetic forming.

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In recent years, the demands on lightweight constructions with respect to their functional qualities and their potential to save resources by reducing weight have increased significantly. Tailor-made components with functionally graded properties manufactured by a novel so-called friction-spinning process meet these demands very well. This new process combines elements from metal spinning and friction welding to a new thermo-mechanical process for the manufacturing of complex hollow parts made of tubes, profiles, or sheet metals. In the process a workpiece, for example a tube, is set into rotation in a conventional spinning machine while a pressure or friction plate works in axial direction on the tube end. In the contact zone the temperature increases strongly by friction. A further movement of the friction plate and optional supplemental forming tools allow the deformation of the warm material and the generation of the desired geometry. With this new process it is possible to extend existing forming limits and to produce complex geometries like flanges or hollow structures, which are not producible by conventional processes. Furthermore, it is possible to influence the workpiece properties or grain structure locally in a defined way. It is possible to realize intense grain refinement in the deformation zone during this thermo-mechanical forming operation.