Abstract: An efficient and effective process for manufacturing of hardened aluminum components is achieved by coordinating the material preparation steps with the forming steps. The resulting product is a hardened aluminum component with desirable strength characteristics. The process includes initial heating of sheet material in order to prepare it for further processing. The sheet material is then quenched to promote appropriate material conditioning. A product forming sub-process is then undertaken in a relatively short period of time following the quenching. The product forming is done while the material is in a relatively ductile condition, thus easing forming operations, and avoiding product spring-back problems. Lastly, the component is naturally aged, to provide the final hardening operations. The resulting product has very desirable strength characteristics, due to the combined forming and hardening process.

Abstract: By utilizing a roll bonding process and appropriately forming steps, a load bearing structure is created which is capable of handling and appropriately transferring loads. One preferred method includes the combination of roll bonding and hydroforming to efficiently create structural components. While various product configurations are possible, one version includes a waffle-type structure produced by appropriate roll bonding of material sheets. This waffle-type structure can also undergo additional forming steps to create several structural components capable of handling and carrying loads in a very efficient and effective manner. More significantly, this process enables the use of structural aluminum for load bearing components which are efficiently and cost effective when manufactured.

Abstract: Link arms for use in suspension systems are produced through an extrusion and friction stir welding process. Blocks having an eye and a planar body section are formed through an extrusion process. These sections are then paired together and joined through friction stir welding. The welded joint(s) is/are positioned in such a location so as to not impact the structural integrity of the completed component. Through this process it is possible to construct cost competitive link arms having the same or better structural integrity as previously employed steel link arms while achieving dramatic weight reductions.

Abstract: A method for joining together two superimposed sheet metal layers includes clamping the sheet metal layers together on a base and positioning a resiliently deformable hemming bead adjacent the superimposed layers. One of the layers includes an outer peripheral flange that extends beyond the outer peripheral edge of the other layer. An anvil has a lower face that follows the bead around the periphery of the superimposed layers and presses against the bead to deform the bead toward the flange. Deformation of the hemming bead causes the peripheral flange of the one layer to bend around the peripheral edge of the other layer in a single operation to thereby join the superimposed sheet metal layers together.

Abstract: A stir weld tool of the present invention is used to weld two pieces of metal together through frictional heating, plasticizing, mixing, and forging of the plasticized metal into a uniform weldment. The stir weld is accomplished by rotating the stir weld tool with a pin having at least one boss on its surface to create the mechanical friction in the metal in contact with the rapidly rotating pin. As the rotating pin travels along the weld joint, the plasticized metal of the work pieces is extruded to the back face of the pin while undergoing a mechanical stirring and forging from action imparted by the at least one boss on the surface of the pin, and while confined from above by the pressure exerted on the metal by a shoulder on the stir weld tool.

Abstract: The three dimensional probe device of the present invention is mountable on a working end of a fully automated and articulated robotic arm movable through at least five degrees of axial freedom in a global dimensional reference. The three dimensional probe device comprises a base, a carriage, a probe, a Z axis measuring apparatus and a tilt measuring apparatus. The probe tip contacts the work piece surface to be traced with deflections in the workpiece seam or path resulting in movement of the carriage and probe. The probe includes a plate and a ball which is pivotable in a ball socket portion of the carriage. Movement of the carriage in relation to the base provides measurement data for rotational change in the direction of the workpiece path or seam. Tilting of the probe provides measurement data for translational change in the direction of the workpiece path or seam.