Abstract: A tubular bumper beam for automobiles includes a rollformed tubular beam and tubular inserts positioned transversely in end sections of the beam. The illustrated tubular insert includes front and rear ends positioned adjacent the front and rear walls of the tubular beam in a manner that reinforces the front and rear walls for improved corner impact strength. Material is extruded from the beam walls into the ends of the insert to form deformed tubular portions that telescopingly extend into the tubular insert to retain the insert in the beam, and further include radiused annular root sections that connect the tubular portions with the walls of the beam, and still further optionally include dished areas around the root sections that help stabilize the beam walls. A method related to the above is also disclosed.

Abstract: A tubular bumper beam for automobiles includes a rollformed tubular beam and tubular inserts positioned transversely in end sections of the beam. The illustrated tubular insert includes front and rear ends positioned adjacent the front and rear walls of the tubular beam in a manner that reinforces the front and rear walls for improved corner impact strength. Material is extruded from the beam walls into the ends of the insert to form deformed tubular portions that telescopingly extend into the tubular insert to retain the insert in the beam, and further include radiused annular root sections that connect the tubular portions with the walls of the beam, and still further optionally include dished areas around the root sections that help stabilize the beam walls. A method related to the above is also disclosed.