flexible metal bellows
A flexible metal bellows is an engineered component consisting of a series of one or more convolutions (the corrugated parts) that allow it to flex, compress, and stretch in response to applied forces, pressure, or temperature changes. Think of it as an accordion-like element made of metal, designed for precise movement and sealing in demanding environments.
They are fundamentally different from rubber hoses or plastic bellows, as they are designed to handle extreme temperatures, pressures, corrosive media, and require high cycle life.
Manufacturing Processes
The manufacturing method significantly impacts the bellows' performance characteristics (flexibility, pressure rating, and stroke length).
- Hydroforming: A metal tube is placed in a die and expanded into its convoluted shape using high-pressure hydraulic fluid. This is a cost-effective method for simpler, lower-pressure bellows.
- Pneumatic Forming: Similar to hydroforming but uses compressed air instead of fluid. Often used for thin-walled bellows.
- Electrodeposition (EDM): A metal is electroplated onto a sacrificial aluminum mandrel in the shape of the bellows. The mandrel is then dissolved away. This creates a seamless, very thin-walled, and highly flexible bellows, ideal for sensitive applications like sensors and aerospace.
- Rolling (Disk/Diaphragm): Individual diaphragms are stamped from metal sheet and then welded together at their inner and outer diameters. This method produces bellows with very high precision and high-pressure capability but is generally more expensive.
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