Axial load support member and method of manufacture

A method of making an axial load support member, comprising:

• a) providing at least three chamber profile preforms, including
• for each preform
• producing a pair of generally flat sheet metal walls having a common shape with the other wall of the pair,
• wherein each of the walls of the pair is bounded by edges, where the edges include a straight linear wall edge portion, and
• wherein at least one of the walls of the pair includes a preform opening,
• sealing the edges of each of the walls together in fluid tight engagement, wherein the walls bound a hermetically sealed empty chamber within the preform that is in fluid communication with the preform opening, and wherein the adjacent sealed wall edge portions comprise an external linear preform portion,
• and subsequent to (a) in any order
• b) joining the at least three preforms together in fixed operative connection along the linear preform portions, wherein the joined linear preform portions of the preforms extend along a central member axis,
• c) delivering fluid pressure through the respective preform opening of each respective preform to the respective chamber to deform each respective preform such that the walls of each respective preform in axially transverse cross-section extend further away from one another with increased radial distance from the central member axis.

An article of manufacture, comprising:

• an axial load support member including
• at least three pressure deformed chamber profile preforms, wherein each preform
• includes a pair of sheet metal walls having a common shape with edges including a linear wall edge portion,
• wherein the walls of the respective preform are sealed together along the respective edges thereof such that the sealed edges bound a hermetically sealed chamber within the preform, and the wall edge portions comprise an external linear preform portion,
• wherein each of the of the at least three preforms are joined together along each respective linear preform portion such that the linear preform portions of the preforms extend along a central member axis, and
• wherein each of the deformed preforms include respective pressure deformed walls that in axially transverse cross-section extend further away from one another with increased radial distance away from the central member axis.