Abstract: A method of manufacturing a reinforcement assembly for a truck bed is provided. The method includes roll-forming an aluminum sheet to form a cross-member having a base, a pair of opposing sidewalls extending from the base, and a pair of flanges each extending from one of the sidewalls and substantially parallel with the base. The method includes extruding an aluminum reinforcement member, and attaching the reinforcement member to the cross-member to space the cross-member from a frame rail of the truck.

Abstract: A vehicle includes a pair of longitudinal frame rails and a bed above the frame rails. A plurality of roll-formed aluminum cross-members contact the bed and are disposed between the bed and the frame rails for additional support of the bed. Extruded aluminum spacers are disposed between and in contact with the one of the cross members and one of the frame rails. A crush tube is spin-welded to the spacer and contacts the underside of the bed for additional support to inhibit downward relative movement of the bed. The crush tube is formed with a longitudinal hole extending therethough to receive a fastener that extends from above the truck bed, through the crush tube hole, through the cross-member and spacer, and into the frame rail.

Abstract: A friction-welded ground assembly that includes an alloy substrate with a clearance hole; an aluminum alloy weld nut having a bolt bore and an outer wall; and a grounding bolt. The bore is located substantially within the clearance hole and a portion of the outer wall is joined to the substrate at a friction-welded attachment. Further, the bolt is threaded within the bore. In addition, a method for making a ground includes the steps: rotating an aluminum alloy weld nut having an outer wall at a predetermined speed; lowering the outer wall of the rotating nut into contact with an aluminum alloy substrate to generate a frictional force for a friction time; arresting the rotation of the nut; and applying an axial forging force to the outer wall and the substrate for a forging time.

Abstract: A friction-welded ground assembly that includes an alloy substrate with a clearance hole; an aluminum alloy weld nut having a bolt bore and an outer wall; and a grounding bolt. The bore is located substantially within the clearance hole and a portion of the outer wall is joined to the substrate at a friction-welded attachment. Further, the bolt is threaded within the bore. In addition, a method for making a ground includes the steps: rotating an aluminum alloy weld nut having an outer wall at a predetermined speed; lowering the outer wall of the rotating nut into contact with an aluminum alloy substrate to generate a frictional force for a friction time; arresting the rotation of the nut; and applying an axial forging force to the outer wall and the substrate for a forging time.

Abstract: A friction-welded ground assembly that includes an alloy substrate with a clearance hole; an aluminum alloy weld nut having a bolt bore and an outer wall; and a grounding bolt. The bore is located substantially within the clearance hole and a portion of the outer wall is joined to the substrate at a friction-welded attachment. Further, the bolt is threaded within the bore. In addition, a method for making a ground includes the steps: rotating an aluminum alloy weld nut having an outer wall at a predetermined speed; lowering the outer wall of the rotating nut into contact with an aluminum alloy substrate to generate a frictional force for a friction time; arresting the rotation of the nut; and applying an axial forging force to the outer wall and the substrate for a forging time.

Abstract: A method of manufacturing a reinforcement assembly for a truck bed is provided. The method includes roll-forming an aluminum sheet to form a cross-member having a base, a pair of opposing sidewalls extending from the base, and a pair of flanges each extending from one of the sidewalls and substantially parallel with the base. The method includes extruding an aluminum reinforcement member, and attaching the reinforcement member to the cross-member to space the cross-member from a frame rail of the truck.

Abstract: A cargo bed assembly for a pickup truck includes an aluminum truck bed above a pair of frame rails. A plurality of roll-formed 6000-series aluminum cross-members extend along a width of the truck bed and contact the underside of the truck bed. The cross-members include longitudinal channels. Each cross-member contacts a pair of extruded 6000-series aluminum spacers underneath the cross-member at spaced locations to align with the frame rails. The spacers contact the frame rails and at least partially surround a portion of the outer surface of the cross-members to separate the cross-members from the frame rails.

Abstract: A vehicle includes a pair of longitudinal frame rails and a bed above the frame rails. A plurality of roll-formed aluminum cross-members contact the bed and are disposed between the bed and the frame rails for additional support of the bed. Extruded aluminum spacers are disposed between and in contact with the one of the cross members and one of the frame rails. A crush tube is spin-welded to the spacer and contacts the underside of the bed for additional support to inhibit downward relative movement of the bed. The crush tube is formed with a longitudinal hole extending therethough to receive a fastener that extends from above the truck bed, through the crush tube hole, through the cross-member and spacer, and into the frame rail.

Abstract: A vehicle includes a pair of longitudinal frame rails and a bed above the frame rails. A plurality of roll-formed aluminum cross-members contact the bed and are disposed between the bed and the frame rails for additional support of the bed. Extruded aluminum spacers are disposed between and in contact with the one of the cross members and one of the frame rails. A crush tube is spin-welded to the spacer and contacts the underside of the bed for additional support to inhibit downward relative movement of the bed. The crush tube is formed with a longitudinal hole extending therethough to receive a fastener that extends from above the truck bed, through the crush tube hole, through the cross-member and spacer, and into the frame rail.

Abstract: A cargo bed assembly for a pickup truck includes an aluminum truck bed above a pair of frame rails. A plurality of roll-formed 6000-series aluminum cross-members extend along a width of the truck bed and contact the underside of the truck bed. The cross-members include longitudinal channels. Each cross-member contacts a pair of extruded 6000-series aluminum spacers underneath the cross-member at spaced locations to align with the frame rails. The spacers contact the frame rails and at least partially surround a portion of the outer surface of the cross-members to separate the cross-members from the frame rails.

Abstract: A vehicle includes a pair of longitudinal frame rails and a bed above the frame rails. A plurality of roll-formed aluminum cross-members contact the bed and are disposed between the bed and the frame rails for additional support of the bed. Extruded aluminum spacers are disposed between and in contact with the one of the cross members and one of the frame rails. A crush tube is spin-welded to the spacer and contacts the underside of the bed for additional support to inhibit downward relative movement of the bed. The crush tube is formed with a longitudinal hole extending therethough to receive a fastener that extends from above the truck bed, through the crush tube hole, through the cross-member and spacer, and into the frame rail.

Abstract: A friction-welded ground assembly that includes an alloy substrate with a clearance hole; an aluminum alloy weld nut having a bolt bore and an outer wall; and a grounding bolt. The bore is located substantially within the clearance hole and a portion of the outer wall is joined to the substrate at a friction-welded attachment. Further, the bolt is threaded within the bore. In addition, a method for making a ground includes the steps: rotating an aluminum alloy weld nut having an outer wall at a predetermined speed; lowering the outer wall of the rotating nut into contact with an aluminum alloy substrate to generate a frictional force for a friction time; arresting the rotation of the nut; and applying an axial forging force to the outer wall and the substrate for a forging time.

Abstract: A cargo bed assembly for a pickup truck includes an aluminum truck bed above a pair of frame rails. A plurality of roll-formed 6000-series aluminum cross-members extend along a width of the truck bed and contact the underside of the truck bed. The cross-members include longitudinal channels. Each cross-member contacts a pair of extruded 6000-series aluminum spacers underneath the cross-member at spaced locations to align with the frame rails. The spacers contact the frame rails and at least partially surround a portion of the outer surface of the cross-members to separate the cross-members from the frame rails.

Abstract: Various embodiments may include determining a material utilization for one or more assemblies having a plurality of parts. Offal data for one or more parts comprising one or more part assemblies and a blank material utilization status for each of the one or more part assemblies may be received. The blank material utilization status for the one or more part assemblies may be based on a blank material utilization status for each of the one or more parts. The offal data may be standardized to obtain standardized offal data. One or more offal utilization assignments for the part assemblies having a plurality of parts may be determined based on the standardized offal data and the blank material utilization status for the part assemblies. The offal utilization assignments may then be transmitted for assignment to the one or more part assemblies.

Abstract: Various embodiments may include determining a material utilization for one or more assemblies having a plurality of parts. Offal data for one or more parts comprising one or more part assemblies and a blank material utilization status for each of the one or more part assemblies may be received. The blank material utilization status for the one or more part assemblies may be based on a blank material utilization status for each of the one or more parts. The offal data may be standardized to obtain standardized offal data. One or more offal utilization assignments for the part assemblies having a plurality of parts may be determined based on the standardized offal data and the blank material utilization status for the part assemblies. The offal utilization assignments may then be transmitted for assignment to the one or more part assemblies.

Abstract: An automotive vehicle body includes a generally tubular, hydroformed cowl with integral mounting flanges which are welded to an engine compartment structural member and a cowlside member. The cowl may be hydroformed from several different preforms having both symmetrical and asymmetrical geometric characteristics.