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.

Abstract: A tool for forming a shaped product has a support body that is fabricated from a first material, such as for instance cast iron. The first material defines a first portion of a forming surface of the tool and has a feature supported thereon. The feature has a layer of a second material that is supported on the first material of the support body, a layer of a third material that is supported on the layer of the second material and a layer of a fourth material that is supported on the layer of the third material. The layer of the fourth material, such as for instance a tool steel alloy, defines a second portion of the forming surface of the tool. During use the first portion of the forming surface and the second portion of the forming surface cooperate to form a desired shape of the shaped product.

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 method of manufacturing a steel part including hot stamping followed by trimming, piercing, or flanging, without delayed fracture and without the need for annealing, is provided. The method includes heating a blank formed of a steel material, forming the blank between a pair of dies, and quenching the blank. The temperature drop in select areas of the blank is reduced, which limits the amount of martensite formed in the select areas, but allows martensite to form in other areas. The dies can be formed with modified materials or modified cooling channels to limit the amount of martensite formed in the select areas of the blank. The select areas are softer than the other areas and can be subsequently trimmed, pierced, or flanged without the delayed fractures.

Abstract: An apparatus for forming a three-dimensional (3D) object includes a 3D printing head, for fabricating a first portion of the 3D object by forming a plurality of successive layers of a first material. The apparatus also includes a delivery head for fabricating a second portion of the 3D object by dispensing onto the first portion of the 3D object a plurality of layers of a continuous-fiber reinforced second material. Further, the delivery head includes comprising a roller for pressing the continuous-fiber reinforced second material into place during the dispensing thereof. A controller controls the 3D printing head and the delivery head to cooperatively form the 3D object, based on a dataset corresponding to a 3D object model.

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 system for producing a vehicle body assembly is provided. The system comprises an assembly station including a press and a transfer system configured to transfer a metal material to the press. The press is configured to form a vehicle body member from the metal material, and the same press is also configured to connect the vehicle body member with at least one additional vehicle body member to form the vehicle body assembly.

Abstract: In accordance with the present invention, there is provided an electromagnetic shielding composition. The electromagnetic shielding composition in accordance with the broad aspects of the present invention includes from about 40% to 60% by volume of a sheet molding composition filled with an effective amount of carbon fibers for shielding of electromagnetic radiation from the electrical systems in an at least partially electrically driven vehicle.

Abstract: A lightweight vehicle pan assembly and for attachment to a vehicle frame via welding includes at least one metal flange and a molded pan body. The at least one metal flange has a weld portion adapted for welded attachment to the vehicle frame and an interface portion extending from the weld portion. The molded pan body has a base wall and at least one side wall extending upward from the base wall. The interface portion of the at least one metal flange is embedded in the at least one side wall of the molded pan body. The interface portion includes at least two rows of apertures defined therein for increasing a bond strength between the at least one metal flange and the molded pan body.

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: A system and method for orienting a workpiece on an assembly line to prepare the workpiece for an operation is provided. The method includes positioning a flexible fixture on the assembly line. The flexible fixture has a base and at least one adjustable component. The workpiece is positioned on the flexible fixture. A first orientation of the workpiece relative to the flexible fixture is detected with a detection device and transmitted to a calibrator. The calibrator determines a difference between the detected first orientation of the workpiece and a predetermined fixture orientation and transmits instructions from the calibrator to the flexible fixture to move the workpiece from the detected first orientation to the predetermined fixture orientation. The workpiece is moved with the at least one adjustable component into the predetermined fixture orientation and is fixedly held with the adjustable component.

Abstract: A process for making a shaped-part from a heat-treatable aluminum alloy blank comprises providing the blank in a hardened temper state, for instance the T6 or another suitable temper state. The as-provided blank is subjected to selective heating, such that a first portion of the blank is heated to a predetermined first temperature for a predetermined first length of time and a second portion of the blank is heated to a predetermined second temperature for a predetermined second length of time. The heated blank is then formed into the desired shape of the shaped-part, and is cooled to ambient temperature. The selective heating substantially increases ductility to facilitate forming of the blank into the desired shape of the shaped part, and provides desired mechanical properties within first and second portions of the shaped part corresponding to the first and second portions of the blank.

Abstract: The twist axle assembly includes a pair of spaced apart trailing arms and a twist beam of which extends in a first direction between the trailing arms. The twist beam includes a pair of end portions and a middle portion. The twist beam further has a pair of side walls and at least one additional wall that extends between the side walls. The side walls in the middle portion are generally parallel with the side walls of the end portions. The twist beam is generally hour-glass shaped with the middle portion having a first width and the end portions have a greater second width. The twist beam also tapers from the first width of the middle portion to the second widths of the end portions for gradually increasing a torsional stiffness from the middle portion to the end portions.

Abstract: Sheet metal is provided as a template to create a finished product. After various metal transformation techniques are performed on the sheet metal, the sheet metal may be converted to the finished product. The sheet metal manipulation may encompass different techniques, such as thinning, bending, cutting, and the like. The manipulated sheet metal may be sourced for various products, such as a body of a vehicle. The aspects disclosed herein combine various tests employed to detect the integrity of the sheet metal transformation into a singular output.

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 process includes disposing a mandrel assembly within a mold cavity bounded by mold forming surfaces. The mold is closed, first portions of the mandrel assembly seal against mold forming surfaces, and a continuous volume shaped as a node element is defined between second portions of the mandrel and the mold forming surfaces. A composite material is injected into the mold cavity filling the continuous volume, and cured forming the node element. The mandrel assembly is removed in sections exposing a node element opening. Tube-skeletons are inserted one each into openings of the node element, each tube-skeleton comprises foam core supported glass or carbon fabric materials. A resin material is injected into the mold cavity, such that the resin material permeates through the fabric material into a node element interior via the openings. The injected resin material is cured, thereby forming tube elements joined to the node element.

Abstract: The twist axle assembly includes a pair of spaced apart trailing arms and a twist beam which is made of a single piece and is operably connected with the trailing arms. The twist beam has a top wall, a bottom wall and a pair of side walls. The twist beam presents a pair of end portions which are bent to present edges that face towards one another when viewed in cross-section, and the twist beam presents a middle portion which extends between the end portions. The middle portion has an opening with a generally elliptical shape formed into the bottom wall for reducing a torsion stiffness of the middle portion of the twist beam in comparison to the end portions.

Abstract: A vehicle bumper assembly includes a bumper beam and a crash box. At least one of the bumper beam or the crash box is cast from metal, such as aluminum or magnesium, to reduce weight, reduce manufacturing process steps, and improve performance characteristics of the bumper assembly. In an embodiment, both of the bumper beam and the crash box are cast from metal to establish an integral connection therebetween. One of the bumper beam or the crash box can be open along a top and bottom portion of the bumper assembly and include at least one reinforcing rib cast integral therewith. In an embodiment, both of the bumper beam and the crash box can be open along a top and bottom portion of the bumper assembly and each include at least one reinforcing rib cast integral therewith.

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

Abstract: A longitudinally extending extruded aluminum bumper is constructed and used in a bumper assembly to protect a vehicle from impact. The bumper includes a three wall design, formed by an integrally formed top wall and a bottom wall interconnected by a front vertically extending wall. The top and bottom walls have open ends that are spaced relative to one another to form a longitudinally extending, open-ended channel therebetween. Upwardly extending and downwardly extending flanges are integrally formed with front vertically extending wall and the top and bottom walls of the bumper. The extruded bumper can be attached directly to an end of a vehicle. Impact absorption devices can also be inserted into the longitudinally extending channel of the bumper and abut against the front vertical wall. Welds can be provided in a non-planar manner to connect the impact absorption devices to the bumper.