Abstract: A method for making structural automotive components and the like provides a strip of high strength steel having a selected thickness. A predetermined thickness of a metal coating, such as nickel, is applied to the opposite faces of the steel strip. The coated steel strip is cut to form a blank. The blank is heated in a generally open atmosphere to a temperature in the range of 800° C. to 1000° C. within less than ten minutes, thereby diffusing at least a portion of the metal coating a predetermined distance into the faces of the steel strip portion of the blank to alleviate scale formation, and simultaneously raise the temperature of the blank for hot forming the same. The heated blank is hot formed in a pressing tool, and cooled therein to heat treat the formed component through microstructure phase change, without substantial scale formation, such that the component need not be descaled prior to post-form processing and/or assembly in a vehicle.

Abstract: A structural door beam for vehicles includes an elongate open channel with an open section configuration defined by a central web and at least one side flange. A mounting tab projects outwardly from a side edge of the side flange and has a marginal edge surrounding a generally planar mounting surface configured to support a vehicle motion sensor. An integral reinforcing flange extends along portions of the side flange edge and the mounting tab edge and protrudes laterally at a predetermined angle to define an integral buttress which stiffens the mounting tab to avoid inadvertent activation of the vehicle motion sensor. An integral bead may also be provided to reinforce the mounting tab.

Abstract: An energy absorption impact system for vehicle bumpers and the like includes a mounting plate with a central opening therethrough, and a generally box-shaped sheet metal crush member. The crush member has a top wall, a bottom wall and opposite sidewalls arranged in a generally frustro-pyramidal shape, defining a large end connected with a vehicle bumper, and a small end connected with the mounting plate about the central opening. Impact on the vehicle bumper inelastically deforms the walls of the crush member toward the central opening in the mounting plate to absorb energy associated with the impact.

Abstract: A method of forming a vehicle component, particularly an elongated impact beam, having an open section structure, in a manner to provide predetermined strategically strengthened portions, comprising the steps of cold forming unhardened steel into a workpiece having mounting surfaces, selectively fixturing the mounting surfaces, static induction heating the workpiece with lengthwise surface eddy currents on selected portions, followed by quenching of the fixtured heated workpiece to form strengthened portions, and unfixturing the resulting component. Also disclosed is apparatus to accomplish this, and the resulting novel vehicle component.

Abstract: An improved bumper facebar, as well as a method of manufacturing the improved bumper facebar, are disclosed. The bumper facebar includes a steel body having at least one area with improved strength exhibiting selective austinitic-martensitic hardening and a Rockwell hardness greater than 41. Moreover, the steel body includes a metallic coating or plating such as chrome plating to provide a decorative finish. The austinitic-martensitic hardening is not exhibited in the steel at those points providing coupling to other objects. The method of manufacturing the improved bumper facebar includes the steps of stamping a bumper blank from a sheet of steel, forming the desired bumper shape from the bumper blank, and hardening select portions of the bumper shape by heating and cooling the select portions to produce a rockwell hardness greater than 41. The method is well adapted to receive additional steps to improve the facebar hardness and impact characteristics.