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OK I did not know I had one and it's a cool thing. The Caliber seems like a weighty small car but apparently it's lighter than it would otherwise have been.

magnesium alloy is expensive and light weight.

Also other smart things about the bodywork include an extensive use of high-strength and hot-stamped steel in strategic areas (e.g., A- and B-pillars; roof reinforcement) so that there is strength without a weight penalty (by using four grades of high-strength steel for approximately 40% of the structure the weight savings are some 44 lb.). There’s dual-phase advanced high-strength steel used for the front and rear rails, tunnel reinforcement, and floor cross members.

Chrysler has been deploying hydroformed components on its trucks; with the Caliber it brings hydroforming to the compact car, with a hydroformed front closure and upper cross member.

In press forming, flat sheets are formed between dies. The die set usually has a static face on which the sheet (blank) is secured and the mating die is depressed - this latter die is called the punch. The major advantage of forming processes is that they avoid the waste of material as happens in machining. Productivity can also be very high compared with machining. The final properties of the metal in the formed state may also be superior to those in the blank.

Hydroforming is a relatively new process, popularised by design studies which suggest that automobiles can be made much lighter by using hydroformed components made of steel. Structural strength and stiffness can be improved and the tooling costs reduced because several components can be consolidated into one hydroformed part. Components manufactured by forming can springback, meaning that the undergo elastic distortion on removing the component from the die. This effect is apparently smaller in hydroformed components.

The process uses a blank with a closed-form, such as a cylinder, internally pressurised using fluid. The fluid is frequently water. The applied pressure is usually in the range 80-450 MPa. Its resultant plastic expansion is confined in a die of the desired shape.
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