Abstract: A multi-piece siderail is fabricated for use as a truck frame which has potential cost and weight reductions while also providing superior weight loading characteristics. Each section of the multi-piece siderail includes a webbed portion having longitudinal ribs that form alternating protruding and recessed sections. An upper and a lower flange are provided on each section and each flange is formed with a stepped, lipped configuration. The unique structure of each section provides increased rigidity and support to that section and also allows for a nesting arrangement between each of the three components. Furthermore, this structure provides multiple attachment zones throughout the frame—two zones on each flange and three zones on the front and rear section webs and five zones on the center section web. Each of these attachment zones are surrounded by a work hardened corner to provide reinforcement.

Abstract: A control arm used as a suspension link within a vehicle suspension system has two similar members. Each member has a substantially W shaped cross section and circular endplates. The endplates are coupled together with bushings that include a compressible member. During normal loading, this bushing arrangement keeps the two members spaced apart. This allows each member to bend and flex when subjected to longitudinal forces. As transverse loading occurs, the two members are caused to move together, and eventually abut one another. This abutment greatly increases the overall strength of the control arm, allowing it to withstand severe transverse forces without buckling.

Abstract: A method of connecting elements in a vehicle frame includes fixing the elements in a desired orientation, positioning dies to surround a portion of each element, and introducing material into the die cavity thereby casting a node around the elements.

Abstract: Tubular members for use in vehicle frames are easily and economically produced using a hydroforming process in which a high pressure fluid is presented to the interior of a tubular member, thus causing the tube to expand to meet the interior walls of a forming die. Tubular members can be formed having significant variations in their circumference, diameter along their lengths, or gage along their lengths by using a stamped blank having a predetermined shape which is formed into a preformed tube which roughly mirrors the shape of the desired finished tubular member.

Abstract: A method of welding together a motor vehicle structural assembly is available. The vehicle structural assembly includes a boxed member including an outboard wall, a top wall, a bottom wall and an inboard wall spaced from the outboard wall. The inboard wall has an opening therein. The motor vehicle structural assembly also includes a cylindrical support including a first end and a shoulder spaced from the first end at least the distance the boxed member inboard wall is spaced from the boxed member outboard wall. The method comprises spinning the support and advancing the support through the inboard wall opening so that the support first end is friction welded to the outboard wall and so that the support shoulder is friction welded to the inboard wall.

Abstract: The invention provides an automated system for welding a first metal part to a second metal part. The system includes a trainable articulated arm, and a moving mechanism for moving the arm. The moving mechanism comprises servos connected to the arm for moving the arm, and a robot controller connected to the mechanized means for controlling the movement of the articulated arm. The system further includes a welding torch, and a probe with physical dimensions comparable to the torch. The probe includes a seam tracking mechanism for tracking the location of a weld seam in response to movement of the probe along the seam, and a connector for transmitting probe movement to the controller. The system further includes a holder mounted on the articulated arm for interchangeable receiving the torch and the probe so that the torch and the probe assume essentially the same position relative to the arm. The invention also provides a method of welding a first metal part to a second metal part using the above system.

Abstract: A coating composition for preventing corrosion of a substrate including corrodable material, the coating composition comprising: a cycloaliphatic epoxy compound; a polyester compound; and a catalyst.