Abstract: A vehicle roof stiffener includes at least one fiber reinforced polymer (FRP) portion and at least one metal or metal alloy portion. The FRP portion includes at least one transition structure including a metal or a metal alloy. At least some of the fibers of the FRP portion are embedded in the transition structure. The metal or metal alloy portion is secured to the transition structure of the FRP portion. In an example vehicle roof stiffener, the metal portion extends parallel to a longitudinal axis of a vehicle, and the FRP portion extends transverse to the longitudinal axis. The example vehicle roof stiffener may include a front FRP portion, a rear FRP portion, and two metal side portions. The metal side portions and the FRP portions may be joined by welding the transition structures to the metal portions.

Abstract: A method of adding a reinforcement to a metal blank prior to a forming process. The reinforcement is attached via ultrasonic additive manufacturing (UAM) to create a composite blank which is then subjected to a forming process to bend and deform the composite blank and form a reinforced vehicle component. The reinforcement is placed on the metal blank such that after being subjected to the forming process, there is reinforcement in key areas of the formed vehicle component. The reinforcement results in the final formed vehicle component having enhanced properties such as lower density, increased strength, stiffness, or energy absorption capabilities.

Abstract: A vehicle roof stiffener includes at least one fiber reinforced polymer (FRP) portion and at least one metal or metal alloy portion. The FRP portion includes at least one transition structure including a metal or a metal alloy. At least some of the fibers of the FRP portion are embedded in the transition structure. The metal or metal alloy portion is secured to the transition structure of the FRP portion. In an example vehicle roof stiffener, the metal portion extends parallel to a longitudinal axis of a vehicle, and the FRP portion extends transverse to the longitudinal axis. The example vehicle roof stiffener may include a front FRP portion, a rear FRP portion, and two metal side portions. The metal side portions and the FRP portions may be joined by welding the transition structures to the metal portions.

Abstract: A vehicle roof stiffener includes at least one fiber reinforced polymer (FRP) portion and at least one metal or metal alloy portion. The FRP portion includes at least one transition structure including a metal or a metal alloy. At least some of the fibers of the FRP portion are embedded in the transition structure. The metal or metal alloy portion is secured to the transition structure of the FRP portion. In an example vehicle roof stiffener, the metal portion extends parallel to a longitudinal axis of a vehicle, and the FRP portion extends transverse to the longitudinal axis. The example vehicle roof stiffener may include a front FRP portion, a rear FRP portion, and two metal side portions. The metal side portions and the FRP portions may be joined by welding the transition structures to the metal portions.

Abstract: A method of adding a reinforcement to a metal blank prior to a forming process. The reinforcement is attached via ultrasonic additive manufacturing (UAM) to create a composite blank which is then subjected to a forming process to bend and deform the composite blank and form a reinforced vehicle component. The reinforcement is placed on the metal blank such that after being subjected to the forming process, there is reinforcement in key areas of the formed vehicle component. The reinforcement results in the final formed vehicle component having enhanced properties such as lower density, increased strength, stiffness, or energy absorption capabilities.

Abstract: A vehicle roof stiffener includes at least one fiber reinforced polymer (FRP) portion and at least one metal or metal alloy portion. The FRP portion includes at least one transition structure including a metal or a metal alloy. At least some of the fibers of the FRP portion are embedded in the transition structure. The metal or metal alloy portion is secured to the transition structure of the FRP portion. In an example vehicle roof stiffener, the metal portion extends parallel to a longitudinal axis of a vehicle, and the FRP portion extends transverse to the longitudinal axis. The example vehicle roof stiffener may include a front FRP portion, a rear FRP portion, and two metal side portions. The metal side portions and the FRP portions may be joined by welding the transition structures to the metal portions.

Abstract: A vehicle system and method includes a primary vehicle (PV) and an auxiliary vehicle (AV) selectively connectable to the primary vehicle. The PV and AV vehicles each having an ECU, a propulsion system a braking system, and a directional control system for steering at least one wheel thereon. The ECU of the PV and the ECU of the AV in communication with one another to form an interactive control system that control operation of the systems of the PV and the AV when connected to one another. The vehicle system also includes a docking system for connecting the AV and the PV. The docking system includes an automatic docking actuator that automatically connects the AV to the PV when actuated. Optionally, a remote control device communicates with the ECU of the AV for controlling the AV through the ECU of the AV when disconnected from the PV.

Abstract: A vehicle system and method includes a primary vehicle (PV) and an auxiliary vehicle (AV) selectively connectable to the primary vehicle. The PV and AV vehicles each having an ECU, a propulsion system a braking system, and a directional control system for steering at least one wheel thereon. The ECU of the PV and the ECU of the AV in communication with one another to form an interactive control system that control operation of the systems of the PV and the AV when connected to one another. The vehicle system also includes a docking system for connecting the AV and the PV. The docking system includes an automatic docking actuator that automatically connects the AV to the PV when actuated. Optionally, a remote control device communicates with the ECU of the AV for controlling the AV through the ECU of the AV when disconnected from the PV.