Abstract: A bumper system including a bumper beam being cast from metal having a front panel and a back panel, extending between a first bumper beam end and a second bumper beam end. A plurality of reinforcing ribs integrally cast with the bumper beam extends between the front panel and the back panel defining a non-uniform cross-sectional profile along a portion of the bumper beam. The front panel includes a front center portion disposed between a pair of front side portions. The back panel includes a back center portion disposed between a pair of back side portions. The front center portion has a front center portion thickness greater than a back center portion thickness. Each of the front side portions has a front side portion thickness being less than a back side portion thickness of adjacent one of the back side portions. Method of manufacturing the bumper system is provided.

Abstract: The present invention is directed to a carrier for an automobile with integrated active ducting. The carrier includes at least one aperture, and at least one louver rotatably mounted in the aperture. Also attached to the carrier is an actuator, and the actuator is connected to the louver. The actuator is operable for moving the louver between an open position and a closed position such that when the louver is in the open position, air flow passes through the aperture.

Abstract: A system and method for automatically moving one or more parts between a bin at a source location and a destination using a robot is provided. The system includes a first vision system to identify a part within the bin and to determine the pick location and pick orientation of the part. A second vision system determines the location and orientation of a destination inside or outside of the bin, which may or may not be in a fixed location. A controller plans the best path for the robot to follow in moving the part between the pick location and the destination. An end effector is attached to the robot for picking the part from the bin, holding the part as the robot moves it, and placing the part at the destination. The system may also check the part for quality by one or both of the vision systems.

Abstract: The method includes the step of positioning the sheets in an at least partially overlapping relationship. The method continues with the step of inserting a rivet that has a height through an overlapping area of the sheets. The method proceeds with the step of, with the rivet at a temperature in the range of 15-30° Celsius, collapsing the rivet between a pair of ramming surfaces to shorten the rivet and partially expand the rivet outwardly to lock the rivet with the sheets. The entire method results in a very strong connection between the sheets and with a great durability at a low cost.

Abstract: A forming system includes a first die, a second die, and a cooling system. A sintered material is formed on opposing portions of the first and second die surfaces to form a relatively low thermal conductive die region. The first die and the second die have opposing, relatively high thermal conductive surfaces to form a relatively high thermal conductive die region. The cooling system is disposed in a thermal conductive relation with the relatively high thermal conductive surfaces. The sintered material on the opposing portions of the first and the second die surfaces cooperate to be on opposite sides of the work piece received in the die cavity. Portions of the work piece in direct contact with the sintered material are cooled at a cooling rate slower than that of portions of the work piece that are in direct contact with the relatively high thermal conductive surfaces.

Abstract: The invention provides a hot stamped structural component (20) for an automotive vehicle, such as a B-pillar, including a first part (22) formed of a high strength steel material joined to a second part (24) formed of a high ductility steel material. The structural component (20) also includes a locally tempered transition zone (26) along the joint (28) to reduce the potential for failure along the joint (28). The transition zone (26) has strength and ductility levels between the strength and ductility levels of the remaining portions of the first and second parts (22, 24). The tempering step can be incorporated into a laser trimming cell or assembly cell, and thus the transition zone (26) can be created without adding an additional process step or increasing cycle time.

Abstract: A die 20 used to form a metal tube into a tubular twist beam part 22 having a U-shaped torsion section 66 is provided. The die 20 includes a punch 44 and side form blocks 34 which simultaneously engage a metal tube and form the metal tube into the tubular twist beam part 22. The form blocks 34 have a curved profile which depends on the desired profile of the tubular twist beam part 22 to be formed. The die 20 includes horizontal spacer blocks 38 and vertical spacer blocks 32 restricting movement of the punch 44 and form blocks 34. The spacer blocks 32, 38 can have various different dimensions and can be easily removed and replaced to adjust the closing position of the die 20 and thus form multiple tubular twist beam parts 22 each having a different dimension and different roll rate.

Abstract: A coating for vehicle components, such as frame assemblies and cradle assemblies formed of steel, is provided. The coating includes a first layer including a high phosphate composition applied to the substrate, and a second layer including wax applied to the first layer. For example, the first layer can include a first inorganic acid, an inorganic salt, a second inorganic acid, nickel salt, and ammonium bifluoride; and the second layer can include petroleum, carbon black pigment, and a corrosion inhibitor, the corrosion inhibitor including magnesium. The coating has been found to improve corrosion resistance when applied to steel substrates, compared to wax coatings which are currently applied to steel substrates.

Abstract: The twist axle assembly includes a pair of trailing arms that are spaced apart from one another in a first direction. The twist axle assembly also includes a twist beam, which has an open shaped cross-sectional shape, that extends in the first direction between a pair of opposing end portions. The open cross-sectional shape of the twist beam includes a base and a pair of side walls. The end portions of the twist beam are fixedly attached with the trailing arms. A pair of beam reinforcements are fixedly attached with the trailing arms and with the base of the twist beam. The beam reinforcements are fixedly attached with the twist beam through at least one of fasteners, adhesives, resistance spot welding, cold metal transfer welding, laser welding, and brazing.

Abstract: A composite liftgate including an inner panel construction having strengthening channel structure in combination with a ribbing. Structural steel reinforcements are bonded to the inner panel where additional strength is needed. Where the extra structure is needed, a minimum amount of steel is used and the structural reinforcement is bonded in place using adhesive. A plurality of access doors are provided that are removable for easier maintenance and repair.

Abstract: A process for removing a material that is adhered to an underlying surface includes using a laser beam to heat the material to reduce the strength of adhesion between the material and the underlying surface. A stream of gas is directed at the heated material to displace the heated material from the underlying surface.

Abstract: A composite liftgate including an inner panel construction having strengthening channel structure in combination with a ribbing. Structural steel reinforcements are bonded to the inner panel where additional strength is needed. Where the extra structure is needed, a minimum amount of steel is used and the structural reinforcement is bonded in place using adhesive. A plurality of access doors are provided that are removable for easier maintenance and repair.

Abstract: A tool for manufacturing blanks and a process for stacking and destacking the blanks in a production line are provided. The tool is incorporated into a blanking die used to trim a metal sheet and form the blanks. When the blanks are stacked, the destacking formations provide gaps between the adjacent blanks. The gaps provide an entry to blast air and thus reliably separate the blanks for pick up, so that only one blank is picked up at a time. The tool includes a deforming unit that has an engagement element for pressing deformations into the metal sheet. The deformations are pressed adjacent to at least one edge of the metal sheet so that when the metal sheet is trimmed, and the blanks are stacked, they are spaced by the deformations by adjacently stacked blanks.

Abstract: A high-pressure die casting apparatus including a shot sleeve extending through a first die half to a molding surface, and a plunger received in the shot sleeve is provided. The shot sleeve includes a side wall presenting a fluid passageway and a partial end wall disposed in a fixed position relative to the side wall. The partial end wall defines a wall opening adjacent the molding surface. Fluid is poured into the shot sleeve while the die apparatus is open, and the partial end wall prevents the fluid from flowing out of the shot sleeve. The plunger then presses the material into the mold cavity until only a portion of the material remains in the shot sleeve and blocks the wall opening. After the solidified material is ejected from the apparatus, the portion of material blocking the wall opening prevents lubricant from entering the shot sleeve.

Abstract: A method for joining a first part formed of an aluminum material to a second part formed of a steel material by metal inert gas welding and cold metal transfer is provided. An aluminum filler material forms a fillet joint between the parts and provides a structure for automotive body applications, such an aluminum bumper extrusion joined to a steel crush box connection. The first part includes a notch for hiding the start and end of the joint. A transition plate formed of a mixture of aluminum material and steel material can be disposed between the first part and the second part to provide the notch. The second part can include a mechanical fastener further joining the parts together. In another embodiment, the second part includes a plurality of dimples and is welded to the first part along the dimples.

Abstract: A multi-window platen oven for simultaneously heating a plurality of blanks, for example aluminum blanks, before forming the heated blanks in a production line is provided. The oven includes a plurality of vertically aligned shelves disposed in an existing press assembly so that no additional floor space is required. The shelves are attachable to an upper press bed and one another. The upper press bed lifts the attached shelves to present an open window for receiving an unheated blank and/or removing a heated blank from the oven. The remaining windows remain closed and continue heating while the blanks are transferred to and from the oven. After closing the one open window, another window opens to receive another unheated blank and/or remove another heated blank. Thus, the multi-window platen oven continuously provides blanks which are ready for warm or hot forming.

Abstract: A final injection molded assembly and process for making same that eliminates paint and reduces areas of wasted chrome material. The final injection molded assembly has at least one first injection molded part of a non-plateable first material, at least one overmolded part of plateable second material, at least one pathway through the assembly and integrated features operable for selectively applying an electric current. The pathway creates a predetermined surface path arrangement for applying chrome to desired predetermined plateable areas. A shot of each material is delivered to an injection molding rotary device to produce the injection molded assembly which is then affixed to a chroming process line where electric current is applied. As the electric current is applied and chrome is delivered only the plateable second material will accept the chrome.

Abstract: A modified compression moulding arrangement where the compression moulding tool has been modified to allow for the use of pre-impregnated pre-form sheets in order to produce class A automotive structural parts in high volume. The pre-impregnated pre-form has continuous un-chopped fibers that extend across an entire length of the pre-impregnated pre-form. The pre-impregnated pre-form is then placed in an open compression moulding tool that has a bottom half and a top half that are movable between an open position and a closed position. When the mould tool is in the closed position, the top half and bottom half create a forming cavity that is defined by a forming surface of the top half and a forming surface of the bottom half. The forming surface of the bottom half has a boundary defined by a run-off edge and an upshear that is necessary for forming a class A structural automotive component using pre-impregnated pre-form material.

Abstract: A method of manufacturing a structural component having tailored material properties by applying an IR-absorbent coating to a substrate formed of a ferrous-based, aluminum-based, magnesium-based, or fiber reinforced composite material is provided. The coating is preferably formed of iron oxide (Fe3O4) decorated multiwall carbon nanotubes. Alternatively, the coating is wax-based or polymer-based and includes TriSilanollsooctylt POSS and additives. Different coating compositions may be applied to different zones of the substrate so that the emissivity coefficient varies along the substrate. The coated substrate is heated and formed between a pair of dies to achieve a complex shape or features. The IR-absorbent coating increases the infrared absorption rate during the heating step, which improves formability of the substrate.

Abstract: A process is disclosed for laser welding sheet metal plates having an anti-corrosion surface layer pre-coat. The plates are arranged one relative to the other in an edge-butting relationship. Using a laser beam having a first beam spot-size, a laser weld joint is formed along the adjacent edges of the sheet metal plates. Subsequent to forming the laser weld joint, a localized anti-corrosion surface layer is formed at least on the laser weld joint. In particular, a laser beam having a second beam spot-size larger than the first beam spot-size is scanned along the laser weld joint. During the scanning, a flow of a powdered anti-corrosion surface layer material is directed toward a portion of the laser weld joint that is being irradiated by the laser beam. The powdered material is melted by the laser beam and forms a layer adhering to the laser weld joint.