Abstract: A die casting apparatus for manufacturing metal parts for automotive vehicle applications is provided. The die casting apparatus includes upper and lower dies presenting forming surfaces and a mold cavity therebetween. A replaceable insert and sub-inserts provide portions of the forming surfaces of the dies in areas most prone to wear and erosion. The replaceable inserts and sub-inserts can be removed and replaced during high volume production, without having to replace the entire die. A wear and/or heat resistant coating can be applied to the inserts and sub-inserts to further increase service life. A plurality of cooling channels can also be formed in the inserts and sub-inserts to improve cycle time and quality of the parts.

Abstract: A heating and cooling system for a vehicle included within a radiator module having a plurality of fins. At least two thermophysical batteries are provided, each including an adsorption bed unit and an evaporator condenser unit. At least one upper coolant line extends along the adsorption bed unit of each of the thermophysical batteries and is configured to be connected to a source of waste heat of the vehicle for transferring heat from the source of waste heat to a coolant contained in the coolant line and to the adsorption bed units to recharge the adsorption bed unit. At least one distribution element configured in discharge mode to convey heated fluids from adjacent the adsorption bed units or cooled fluids from adjacent to the evaporator condenser units to another region of the vehicle.

Abstract: A steel door ring for an automotive vehicle including a reinforcement to increase the strength of desired areas of the door ring is provided. The door ring can be manufactured with reduced cycle time and thus improved efficiency. The method includes hot stamping the reinforcement as part of the same blank used to form the remainder of the door ring. During the hot stamping step, the reinforcement portion used to form the reinforcement is located in a free space, for example in a door opening between pillars and rails. Unlike comparative processes, the reinforcement portion used to form the reinforcement is not welded to a pillar of the door ring prior hot stamping. After hot stamping, the reinforcement is trimmed from the door ring, and then attached in a desired location, for example by welding.

Abstract: The invention provides a method of manufacturing a component formed of an aluminum alloy for use in an automotive vehicle application, for example those requiring high strength, light-weight, and a complex three-dimensional shape. The method begins by providing a blank formed of an aluminum alloy which is already solution heat treated and tempered, and thus has a temper designation of about T4. The method further includes heating the blank to a temperature of 150° C. to 350° C., preferably 190° C. to 225° C. The method next includes quickly transferring the blank to a hot or warm forming apparatus, and stamping the blank to form the complex three-dimensional shape. Immediately after the forming step, the component has a temper designation of about T6, but preferably not greater than T6, and thus is ready for use in the automotive vehicle application without any post heat treatment or machining.

Abstract: An impact absorbing element comprising a tubular body for absorbing the impact energy in a vehicle is proposed, the impact absorbing element having a double honeycomb-shaped cross section and being configured as a 10-face polygonal line, and honeycomb points being configured which are situated at a spacing (b2) from one another of approximately half the overall height (b1) of the impact absorbing element and define a width.

Abstract: A retainer for limited space attachment of a vehicle part with a class A surface to a vehicle. The retainer has a low profile portion and also an attachment base operable for being connected to heat stake ribs of the vehicle part. The attachment base includes at least one attachment aperture to provide attachment with the heat stake ribs. There is provided desired degrees of clip float and/or two-way limited clip float providing desired free movement of the clip when desired.

Abstract: A method and system for detecting edge cracks of an element of a sheet metal product is provided. The method includes calculating a first stress associated with a forming process employing a first die; calculating a second stress associated with a finishing process employing a second die; combining the first stress and the second stress to formulate a total stress; simulating the sheet metal product to produce a benchmark stress; and comparing the total stress and the benchmark stress to determine if the element predictively contains edge cracks.

Abstract: A crossmember for a bumper includes an extruded profile base frame with at least two connecting areas, for attaching the crossmember to a vehicle structure, and which are set at a distance from each other along a longitudinal direction. An extruded reinforcing element is fixedly secured to a rear side of the extruded profile base frame between the at least two connecting areas. The crossmember is weight-optimized and which can be produced in a cost-effective manner.

Abstract: A welding tip (20) for spot welding a first part (22) formed of conductive metal, for example aluminum, to a second part (24) formed of aluminum or another conductive metal, such as steel, is provided. The welding tip (20) includes a notch (30) at a distal end (38) and a convex contact surface (28) extending radially outwardly and upwardly from the notch (30) for engaging a surface of the first part (22). The rotating welding tip (20) forms a depression (32) on the surface of the first part (22) during the welding process. The notch (30) creates a pin (34) in the center of the depression (32) which provides a fixed axis of rotation for the rotating welding tip (20) and prevents the welding tip (20) from moving radially relative to the fixed axis, thereby improving the quality of the final spot weld (36) and reducing process time.

Abstract: A coated steel component is provided. The coated steel component includes a substrate composed of a steel sheet which can be supplied to a hot-forming process. The coated steel component also possesses a non-metallic coating on the basis of silicon, in a layered structure. The layered structure includes three functional layers having the composition SiOxNyCz, wherein x lies between 30 and 70%, y lies between 0 and 35%, and z lies between 0 and 50%.

Abstract: A bumper beam includes an outer portion and an inner portion each extending between a top end and a bottom end. At least one of the outer portion or the inner portion includes a pair of geometrical features each of which are disposed in spaced relationship to one another and adjacent a respective one of the top or bottom ends. A top wall and a bottom wall each extend from one of the geometrical features to the other of the outer portion or the inner portion to interconnect the outer and inner portions of the bumper beam. The geometrical features can be varied in size and shape to change and tune the energy absorption properties of the bumper beam and ultimately provide for a bumper beam that is adaptable and flexible over a range of vehicle applications.

Abstract: The invention relates to a two-part component for a vehicle body comprising an outer sheet (1) and an inner sheet (2), wherein the outer sheet (1) is connected to the inner sheet (2) along their rims at least in one connection section (3) in such a manner that the outer sheet (1) and the inner sheet (2) run parallel to one another in a first region (4) of the outer sheet (1), wherein an adhesive material (5) is introduced in the first region (4) between the outer sheet (1) and the inner sheet (2), and wherein in a second region (6) of the outer sheet (1), the outer sheet (1) is bent against the inner side of the inner sheet (2), wherein in the second region (6) of the outer sheet (1), the outermost rim of the outer sheet (1) is welded to the inner side of the inner sheet along the connection section (3), and to a production method for same.

Abstract: A process is described for laser welding a sheet metal workpiece having an anti-corrosion pre-coat on at least one major surface thereof and having first and second opposite side edges. The sheet metal workpiece is arranged such that the first and second side edges are in contact with one another and such that the at least one major surface faces outwardly. A laser beam having a first beam spot-size, is used to form a laser weld joint between the first and second side edges. Subsequently, a localized anti-corrosion surface layer is formed on the laser weld joint. To this end, 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 laser beam melts the material, which subsequently solidifies to form a layer adhering to the laser weld joint.

Abstract: A tool for hot stamping metal sheets, formed least partially of a base block and a functional layer, is proposed. The functional layer comprises cooling channels and multiple functional layers, which building upon each other create the connection to the base block. The cooling channels are designed as a cooling channel array and are produced in a laser sintering method.

Abstract: A twist axle assembly (20) of a vehicle includes a pair of trailing arms (22) and a twist beam (24) having a base portion (46) extending along an axis (A) between first and second twist beam ends (42, 44). The twist beam (24) includes a pair of side walls (48) extending downwardly from the base portion (46) and each disposed in spaced relationship with the trailing arms (22). At least one mounting bracket (54) extends from a first mounting bracket end (56) disposed in abutting relationship with a respective trailing arm (22) to a second mounting bracket end (58) disposed in overlaying relationship the side walls (48) of the twist beam (24) for allowing the mounting bracket to axially slip or slide along the side walls (48) of the twist beam (24) and provide for lateral or axial adjustment of the twist axle assembly (20) during the manufacturing process.

Abstract: A system for producing components by hot stamping includes a laser cutting station for cutting a plate from a supplied steel-sheet material. The plate has at least one of a predetermined edge-contour and a predetermined cut-out portion for forming a shape of the component. The plate is stored in a storage station, and is subsequently transferred to a furnace station for heating the plate to a predetermined deformation temperature. A press having a hot stamping tool forms the plate into the shape of the component. The system also includes a measuring station disposed downstream of the press for obtaining measurement data relating to the shape of the component that is formed from the plate. The measurement data obtained using the measuring station is provided to a control module of the laser cutting station via a feedback loop.

Abstract: The aspects of the present disclosure include an improved frame-to-bed assembly, which allows the pickup bed to be attached directly to the pickup truck frame without or with the reduced use of cross-sills. Instead, the pickup bed is directly attached to the frame cross-members via an attachment assembly to retain the pickup bed in place.

Abstract: A compact deployable/retractable running board assembly for a motor vehicle including a running board, linkage coupled to the running board, and a motor assembly coupled to an actuator, the running board moveable between at least one stowed position and at least one deployed position. The linkage includes a drive arm connected to a pivot shaft within a housing at a location on the pivot shaft between two bushings that are coupled to the pivot shaft within the housing. The linkage also includes an idler arm connected to a pivot shaft within an idler housing. The actuator is operably coupled to the linkage to cause rotation of the linkage to move the running board between the at least one stowed position generally under the motor vehicle and at least one deployed position to provide a step surface for a user.

Abstract: A part, such as an automotive part, is provided. The part includes at least two work pieces of steel which are joined together at a weld seam which includes at least one of nickel and iron and is substantially entirely free of silicate islands. The part also includes a painted, phosphated or electrocoated coating which is bonded with at least a portion of the substantially entirely silicate island free weld seam.

Abstract: The vehicle suspension component includes first and second trailing arms that are spaced from one another for attachment with vehicle wheels. The suspension component also includes at least one cross-member that is rigidly connected with the first trailing arm and is operably connected with the second trailing arm in a non-rigid manner. A rotation inhibitor operably connects the at least one cross-member with the second trailing arm and resiliently resists rotation of the at least one cross-member relative to the second trailing arm.