Patent ID: 8205475

Claim:
A process for the warm forming of a metal substrate to form a contoured metal part comprising aluminum, or magnesium, comprising: a) supplying a blank of said metal coated with at least one barrier coating of a metal different from the metal of the metal substrate or metal oxide, and at least one warm forming lubricating coating selected from the group consisting of metal(s), non-fugitive high melting point polar polymers, and mixtures thereof, said barrier coat effective in reducing migration of the warm forming lubricating coating into the metal substrate, said coating being substantially continuous before warm forming, or developing a substantially continuous coating during the warm forming process; b) supplying an at least two part mold having a contour in mating mold parts corresponding to the shape of the contoured metal part; c) heating the blank to a warm forming temperature and positioning the blank in the mold; d) closing the mold under pressure to form a warm formed part; and e) removing the warm formed part from the mold, wherein the warm forming temperature is less than 1000° F. and also at least 50° C. below the melting point of the metal substrate.