Abstract: An apparatus for forming a metal article includes a station which receives and supports a workpiece. The station has a source of electrical current and a source of a fluid. The station further includes a first and a second electrode clamp. Each clamp is in electrical communication with the source of current and in fluid communication with the source of fluid. The clamps engage a workpiece and deliver an electrical current and a fluid thereto. The system includes an actuator mechanically associated with at least one of the clamps. The actuator is operable in combination with a clamp to apply mechanical force to the workpiece. The system is operable to selectably control the temperature profile and/or ambient conditions of a workpiece during forming or processing steps. Disclosed are specific systems including modular systems. Also disclosed are methods for using the systems.

Abstract: A roll-formed one-piece vehicle bed member has a plurality of ribs and valleys extending longitudinally along the bed member in sidewardly adjacent, parallel relation. The bed member terminates at front and rear edges wherein preferably along the rear edge of the bed member, rib channels are formed centrally along the end portion of each rib for direct contacting engagement with a rear sill to provide an improved connection therebetween.

Abstract: A method for providing a controlled heating profile in an article being heated in a resistance heating process is provided. The method includes contacting the article with a plurality of electrodes, selecting a first correlated group that includes at least two electrodes, and establishing a flow of electrical current between the electrodes of the first correlated group. The method also includes selecting a second correlated group that includes at least two electrodes, the second correlated group differing from the first correlated group. A flow of electrical current is also established between the electrodes of the second correlated group for the purpose of providing a controlled heating profile for an article undergoing resistance heating.

Abstract: A structural supporting roof pillar for use in a vehicle including an elongated, interiorly hollowed and polygonal shaped body having a selected arcuate lengthwise configuration and corresponding in placement to at least one of an A, B, and C vehicle pillar. A first component supporting flange is integrally formed, such as by overlapping end portions of a roll formed body, and projecting in at least a partially lengthwise extending fashion from a given cross sectional location. A secondary component supporting flange is affixed to a further cross sectional location associated with the body, such as further by welding.

Abstract: A continuous process for producing a shaped metal member from a feedstock comprising a flat web of metal includes a roll-forming station for shaping the web, a cutting station for cutting the shaped web into individual members, and a processing station for altering a physical characteristic of the metal comprising the members. The processing may include heat treating and/or shaping. The process may also be operable to carry out further operations such as marking, inspection, sorting and the like. Also disclosed is an apparatus for carrying out the process.

Abstract: An apparatus for forming a metal article includes a station which receives and supports a workpiece. The station has a source of electrical current and a source of a fluid. The station further includes a first and a second electrode clamp. Each clamp is in electrical communication with the source of current and in fluid communication with the source of fluid. The clamps engage a workpiece and deliver an electrical current and a fluid thereto. The system includes an actuator mechanically associated with at least one of the clamps. The actuator is operable in combination with a clamp to apply mechanical force to the workpiece. The system is operable to selectably control the temperature profile and/or ambient conditions of a workpiece during forming or processing steps. Disclosed are specific systems including modular systems. Also disclosed are methods for using the systems.

Abstract: A reinforcement member for reinforcing an outer panel of a vehicle door includes an upper wall, an outer wall, a leg and a reinforcement beam. The leg extends between a lower end of the upper wall and an upper end of the outer wall. The reinforcement beam is formed at a lower end of the outer wall for reinforcing the outer panel of the vehicle door. A generally S-shaped flange is formed between the lower end of the upper wall and the leg. A portion of the S-shaped flange is substantially parallel with the upper wall so as to define a recess adjacent the S-shaped flange that provides enhanced retention of a door seal thereto.

Abstract: A vehicle box assembly wherein a bed floor and the inner right and left side wall panels are defined by and assembled from two monolithic one-piece integrated side/floor panel members. The two panel members are preferably formed by roll forming a thin metal sheet so that only a single roll-formed panel configuration is required. Subsequent forming operations, such as punching or die forming, are carried out on the roll-formed configuration to create right and left panel members which are assembled to define the floor and opposed inner side panels of the box assembly.

Abstract: An apparatus for forming a metal article includes a station which receives and supports a workpiece. The station has a source of electrical current and a source of a fluid. The station further includes a first and a second electrode clamp. Each clamp is in electrical communication with the source of current and in fluid communication with the source of fluid. The clamps engage a workpiece and deliver an electrical current and a fluid thereto. The system includes an actuator mechanically associated with at least one of the clamps. The actuator is operable in combination with a clamp to apply mechanical force to the workpiece. The system is operable to selectably control the temperature profile and/or ambient conditions of a workpiece during forming or processing steps. Disclosed are specific systems including modular systems. Also disclosed are methods for using the systems.

Abstract: A high strength reinforcing beam structure is provided. The beam structure includes an elongated member, with at least a portion of a length of the member having a cross section which defines a first, a second, a third, and a fourth curved segment. Each of the curved segments has a shape that can be defined by a hyperbolic cosine function. In addition to the high strength reinforcing beam structure, a process for making such a structure is provided. The process includes feeding an elongated member at least partially into a roll forming machine, the machine forming at least a first portion of a length of the elongated member such that the cross section has a first, a second, a third, and a fourth curved segment, each of the curved segments defined by a hyperbolic cosine function.