Abstract: A vehicle includes a traction inverter and an electric motor operable to provide motive power for the vehicle based on electrical power received wirelessly from a modular power system.

Abstract: Aluminum sheet stamping processes are provided that can include heating an aluminum sheet to a first temperature that is greater than ambient temperature; quenching the aluminum sheet to cool the aluminum sheet to a second temperature that is less than the first temperature; after the quenching allowing the aluminum sheet to rest at ambient temperature for at least 24 hours; and stamping the aluminum sheet to form a stamped component. Stamped aluminum components including one or more portions having an HRB hardness of greater than 87 are also provided. Processes are also provided for fabricating an aluminum component from an aluminum sheet. The processes can include modifying formability of at least one discrete portion of an aluminum sheet, and compressing and/or expanding at least a portion of the one discrete portion to form a fabricated component. The fabricated component can include at least one aluminum member comprising a compressed and/or expanded modified discrete portion.

Abstract: A method for joining dissimilar materials is provided. The method includes a solid-state joining process in which a rivet is plunged into a predrilled hole in a top workpiece. When the rivet contacts the bottom workpiece, ultrasonic vibration by oscillatory motion of a sonotrode, such as horizontal, vertical, or rotational motion, creates frictional heat at the interface between the rivet and the lower workpiece. With the aid of frictional heat and axial compression, metallurgical bonding is achieved at the interface between the rivet and the bottom sheet, while being below the melting temperature of the bottom workpiece. The sonotrode is retracted while the rivet remains.

Abstract: A method for joining dissimilar materials is provided. The method includes a solid-state joining process in which a rivet is plunged into a predrilled hole in a top workpiece. When the rivet contacts the bottom workpiece, ultrasonic vibration by oscillatory motion of a sonotrode, such as horizontal, vertical, or rotational motion, creates frictional heat at the interface between the rivet and the lower workpiece. With the aid of frictional heat and axial compression, metallurgical bonding is achieved at the interface between the rivet and the bottom sheet, while being below the melting temperature of the bottom workpiece. The sonotrode is retracted while the rivet remains.

Abstract: A method for installing a self-piercing rivet by introducing acoustic (ultrasonic) vibrational energy is provided. The method includes positioning multiple workpieces between a blank holder and a die, applying ultrasonic vibrations to locally soften the workpieces and driving, using a press tool, the self-piercing rivet into the workpieces, causing the self-piercing rivet to deform in a radially outward direction, thereby joining the workpieces together without thermal processing and without permanent alterations to the microstructure of the workpiece materials.

Abstract: An extrusion apparatus and process are disclosed that produce high-performance extrusion structures. The extrusion apparatus includes a shear tool that applies a rotational shear force and an axial extrusion force to the face of a billet material that plasticizes the billet material. Plasticized material is extruded through an extrusion die along the length of the inner bore of the shear tool which yields hollow and solid extrusion structures. The process refines the microstructures of the extrusion structures and extrusion materials.