Abstract: An efficient and effective process for manufacturing of hardened aluminum components is achieved by coordinating the material preparation steps with the forming steps. The resulting product is a hardened aluminum component with desirable strength characteristics. The process includes initial heating of sheet material in order to prepare it for further processing. The sheet material is then quenched to promote appropriate material conditioning. A product forming sub-process is then undertaken in a relatively short period of time following the quenching. The product forming is done while the material is in a relatively ductile condition, thus easing forming operations, and avoiding product spring-back problems. Lastly, the component is naturally aged, to provide the final hardening operations. The resulting product has very desirable strength characteristics, due to the combined forming and hardening process.

Abstract: By utilizing a roll bonding process and appropriately forming steps, a load bearing structure is created which is capable of handling and appropriately transferring loads. One preferred method includes the combination of roll bonding and hydroforming to efficiently create structural components. While various product configurations are possible, one version includes a waffle-type structure produced by appropriate roll bonding of material sheets. This waffle-type structure can also undergo additional forming steps to create several structural components capable of handling and carrying loads in a very efficient and effective manner. More significantly, this process enables the use of structural aluminum for load bearing components which are efficiently and cost effective when manufactured.

Abstract: An efficient and effective process for manufacturing of hardened aluminum components is achieved by coordinating the material preparation steps with the forming steps. The resulting product is a hardened aluminum component with desirable strength characteristics. The process includes initial heating of sheet material in order to prepare it for further processing. The sheet material is then quenched to promote appropriate material conditioning. A product forming sub-process is then undertaken in a relatively short period of time following the quenching. The product forming is done while the material is in a relatively ductile condition, thus easing forming operations, and avoiding product spring-back problems. Lastly, the component is naturally aged, to provide the final hardening operations. The resulting product has very desirable strength characteristics, due to the combined forming and hardening process.

Abstract: By utilizing a roll bonding process and appropriately forming steps, a load bearing structure is created which is capable of handling and appropriately transferring loads. One preferred method includes the combination of roll bonding and hydroforming to efficiently create structural components. While various product configurations are possible, one version includes a waffle-type structure produced by appropriate roll bonding of material sheets. This waffle-type structure can also undergo additional forming steps to create several structural components capable of handling and carrying loads in a very efficient and effective manner. More significantly, this process enables the use of structural aluminum for load bearing components which are efficiently and cost effective when manufactured.

Abstract: A control arm used as a suspension link within a vehicle suspension system has two similar members. Each member has a substantially W shaped cross section and circular endplates. The endplates are coupled together with bushings that include a compressible member. During normal loading, this bushing arrangement keeps the two members spaced apart. This allows each member to bend and flex when subjected to longitudinal forces. As transverse loading occurs, the two members are caused to move together, and eventually abut one another. This abutment greatly increases the overall strength of the control arm, allowing it to withstand severe transverse forces without buckling.

Abstract: A method for joining together two superimposed sheet metal layers includes clamping the sheet metal layers together on a base and positioning a resiliently deformable hemming bead adjacent the superimposed layers. One of the layers includes an outer peripheral flange that extends beyond the outer peripheral edge of the other layer. An anvil has a lower face that follows the bead around the periphery of the superimposed layers and presses against the bead to deform the bead toward the flange. Deformation of the hemming bead causes the peripheral flange of the one layer to bend around the peripheral edge of the other layer in a single operation to thereby join the superimposed sheet metal layers together.