Abstract: A variable thickness member for a vehicle includes a first portion having a first thickness and a second portion extending from the first portion having a second thickness. The first thickness is different from the second thickness and the first thickness and the second thickness are integral, unitary, and one piece.

Abstract: A hydroformed dovetail joint and method of joining tubular members includes a first hydroformed tubular member having a depression therein and a second hydroformed tubular member having an end. The end of the second hydroformed tubular member is disposed over the depression of the first hydroformed tubular member to join the first hydroformed tubular member and the second hydroformed tubular member together to form a dovetail joint between the first hydroformed tubular member and the second hydroformed tubular member.

Abstract: A hydroformed and roll-formed cross sill assembly for a vehicle and method of making same includes a pair of hydroformed tubular side members. The hydroformed and roll-formed cross sill assembly also includes a roll-formed beam member disposed between the tubular side members and at least one weld to secure the beam member to each of the tubular side members.

Abstract: A grille guard assembly for a vehicle and method of making same includes a hydroformed tubular upper member and a hydroformed tubular lower member. The grille guard assembly also includes at least one inner member interconnecting the upper member and the lower member. The grille guard assembly further includes at least one bracket connected to the lower member for attachment to vehicle structure.

Abstract: A method of progressive hydro-forming of a tubular member includes the steps of positioning a tubular member between open die halves mating with one another to define a first tubular cavity portion in a first stage. The method also includes the steps of progressively closing the die halves and applying hydraulic pressure to expand and conform the tubular member to the first tubular cavity portion in the first stage. The method includes the steps of positioning the expanded tubular member in a second tubular cavity portion in a second stage and progressively closing the die halves to progressively deform the expanded tubular member within the second tubular cavity portion. The method includes the steps of applying hydraulic pressure to expand and conform the expanded tubular member to the second tubular cavity portion in the second stage.

Abstract: A variable thickness member for a vehicle includes a first portion having a first thickness and a second portion extending from the first portion having a second thickness. The first thickness is different from the second thickness and the first thickness and the second thickness are integral, unitary, and one piece.

Abstract: A method of making a pre-formed tubular member includes the steps of providing a tubular member extending longitudinally and providing a bending assembly having a mandrel with at least one ball and a bending die. The method also includes the steps of positioning the at least one ball inside of the tubular member. The method further includes the steps of bending the tubular member about the bend die to form a bent pre-formed tubular member having at least one curved portion having a recess therein.

Abstract: A grille guard assembly for a vehicle and method of making same includes a hydroformed tubular upper member and a hydroformed tubular lower member. The grille guard assembly also includes at least one inner member interconnecting the upper member and the lower member. The grille guard assembly further includes at least one bracket connected to the lower member for attachment to vehicle structure.

Abstract: A structural assembly and method of making same for a vehicle includes a hydroformed tubular member and at least one external reinforcement disposed about and secured to at least a portion of the tubular member.

Abstract: A hydroformed and roll-formed cross sill assembly for a vehicle and method of making same includes a pair of hydroformed tubular side members. The hydroformed and roll-formed cross sill assembly also includes a roll-formed beam member disposed between the tubular side members and at least one weld to secure the beam member to each of the tubular side members.

Abstract: An internally reinforced hydroformed assembly and method of making same includes a hydroformed tubular member and a reinforcement disposed within the hydroformed tubular member prior to hydroforming. The internally reinforced hydroformed assembly and method of making same also includes at least one weld to secure the reinforcement to an interior surface of the hydroformed tubular member.

Abstract: A hydroformed dovetail joint and method of joining tubular members includes a first hydroformed tubular member having a depression therein and a second hydroformed tubular member having an end. The end of the second hydroformed tubular member is disposed over the depression of the first hydroformed tubular member to join the first hydroformed tubular member and the second hydroformed tubular member together to form a dovetail joint between the first hydroformed tubular member and the second hydroformed tubular member.

Abstract: A method of making a pre-formed tubular member includes the steps of providing a tubular member extending longitudinally and providing a bending assembly having a mandrel with at least one ball and a bending die. The method also includes the steps of positioning the at least one ball inside of the tubular member. The method further includes the steps of bending the tubular member about the bend die to form a bent pre-formed tubular member having at least one curved portion having a recess therein.

Abstract: A method of forming a vehicle body side structure assembly includes the steps of providing a plurality of tubular members to form a frame structure and assembling the tubular members together to pre-form the frame structure. The method also includes the step of positioning the pre-formed frame structure between open die halves mating with one another to define a tubular cavity portion. The method includes the step of closing the die halves to capture the pre-formed frame structure within the tubular cavity portion. The method further includes the step of pressurizing an interior of the pre-formed frame structure to expand and conform the pre-formed frame structure to the tubular cavity portion to form a final frame structure.

Abstract: A method of progressive hydro-forming of a tubular member includes the steps of positioning a tubular member between open die halves mating with one another to define a first tubular cavity portion in a first stage. The method also includes the steps of progressively closing the die halves and applying hydraulic pressure to expand and conform the tubular member to the first tubular cavity portion in the first stage. The method includes the steps of positioning the expanded tubular member in a second tubular cavity portion in a second stage and progressively closing the die halves to progressively deform the expanded tubular member within the second tubular cavity portion. The method includes the steps of applying hydraulic pressure to expand and conform the expanded tubular member to the second tubular cavity portion in the second stage.

Abstract: A method of single sided spot welding includes the steps of providing a metal tube having a convex surface portion and providing a metal sheet for welding to the metal tube. The method also includes the steps of contacting the metal sheet with the convex surface portion of the metal tube and contacting the metal sheet with a welding electrode. The method further includes the steps of supplying power to the welding electrode for melting metal and solidifying the molten metal to form a weld nugget between the metal sheet and the metal tube.

Abstract: A method of single sided, spot welding includes the steps of providing a metal tube having a convex surface portion and providing a metal sheet for welding to the metal tube. The method also includes the steps of contacting the metal sheet with the convex surface portion of the metal tube and contacting the metal sheet with a welding electrode. The method further includes the steps of supplying power to the welding electrode for melting metal and solidifying the molten metal to form a weld nugget between the metal sheet and the metal tube.

Abstract: The present invention is for a method of lap joining two tubular members and then hydroforming the tubular assembly. An insert end of the first tubular member is inserted into a receiver end of the second tubular member to form a lap joint. A filler metal ring is placed about the outer periphery of the insert end so that it is adjacent the opening of the receiver end of the second tubular member. Heat is applied to braze or solder the lap joint, forming a tubular assembly. The tubular assembly is then hydroformed during which time a supplementary mechanical lock may be formed in the lap joint.

Abstract: The present invention is for a method of lap joining two tubular members and then hydroforming the tubular assembly. An insert end of the first tubular member is inserted into a receiver end of the second tubular member to form a lap joint. A filler metal ring is placed about the outer periphery of the insert end so that it is adjacent the opening of the receiver end of the second tubular member. Heat is applied to braze or solder the lap joint, forming a tubular assembly. The tubular assembly is then hydroformed during which time a supplementary mechanical lock may be formed in the lap joint.

Abstract: A hydroformed tubular structure includes at least two hydroformed members connected at a joint. At least one of said members includes a flattened portion having opposite sides in engagement. One of the sides engages and is secured to a mating portion of another of the members and a hydroformed conjugate portion is formed in the one side adjacent the flattened portion and is secured in a recess of the other member. A hydroformed structural portion extends from the conjugate portion in a direction away from the flattened portion.