Abstract: Cross-member for a motor-vehicle front suspension, comprising a first structure of metal, a second structure of composite material joined to the first structure and a plurality of mounting members connected to each other by the first structure to allow mounting of one or more components of the front suspension onto the cross-member, wherein the second structure comprises a base body wholly made of a composite material with a polymer matrix and at least one reinforcement element securely connected to the base body in predetermined areas thereof to contribute to the mechanical strength and stiffness of the whole cross-member whereby the second structure includes a main portion extending in a transverse direction, a pair of longitudinal appendages projecting rearwards from the opposite ends of the main portion, and a pair of struts extending upwards each from a respective longitudinal appendage.

Abstract: Cross-member for a motor-vehicle front suspension, comprising a first structure of metal, a second structure of composite material joined to the first structure and a plurality of mounting members connected to each other by the first structure to allow mounting of one or more components of the front suspension onto the cross-member, wherein the second structure comprises a base body wholly made of a composite material with a polymer matrix and at least one reinforcement element securely connected to the base body in predetermined areas thereof to contribute to the mechanical strength and stiffness of the whole cross-member whereby the second structure includes a main portion extending in a transverse direction, a pair of longitudinal appendages projecting rearwards from the opposite ends of the main portion, and a pair of struts extending upwards each from a respective longitudinal appendage.

Abstract: A method for manufacturing a structural element comprises steps of providing separate first and second half-shells made of at least one layer of composite material including a fiber-reinforced polymeric matrix, providing a core made of ductile material, joining the core to the first half-shell such that at least one cavity is defined inside the structural element, and joining the second half-shell to the first half-shell.

Abstract: The manufacturing method comprises the steps of: carrying out one or more forming operations so as to give the desired geometry to the part; and subjecting the part thus formed to a single heat treatment having only a stress relieving treatment, which is preferably carried out at a temperature in the range from 530° C. to 580° C. for a time in the interval from 45 to 60 minutes and is followed by cooling of the part in air. By virtue of the formed part being subjected to a stress relieving heat treatment, the residual stress state due to the initial forming process and to the bead welding, if any, is eliminated or at least significantly reduced.

Abstract: A method for manufacturing a structural element comprises steps of providing separate first and second half-shells made of at least one layer of composite material including a fibre-reinforced polymeric matrix, providing a core made of ductile material Joking the core to the first half-shell such that at least one cavity is defined inside the structural element, and joining the second half-shell to the first half-shell.

Abstract: The cross-member (12) comprises first and second beam elements (20, 22) having an open cross-section and firmly secured to each other so as to enclose a closed cross-section chamber (32) having such shape and sizes as to provide the cross-member (12) with the desired torsional stiffness. A free edge (20a) of the first beam element (20) is firmly secured to the outer surface of an intermediate portion (22c) of the second beam element (22) and a free edge (22a) of the second beam element (22) is firmly secured to the inner surface of an intermediate portion (20b) of the first beam element (20). The two beam elements (20, 22) are advantageously made as stamped sheet metal pieces.

Abstract: A cross-member for a motor-vehicle twist-beam axle suspension includes a single piece of steel that defines a closed cross-section and integrally forms a middle section, a pair of end sections, and a pair of joining sections. The middle section has a center axis extending along a curvilinear path lying in a first plane and a squashed portion extending in a second plane inclined to the first plane. The end sections are adapted to be securely connected to respective trailing arms of the twist-beam axle suspension. Each of the joining sections is interposed between the middle section and the respective end section and defines an opposite concavity with respect to the middle section. A twist-beam axle suspension for a motor vehicle includes the cross-member and a pair of trailing arms. A method produces the cross-member for a motor-vehicle twist-beam axle suspension.

Abstract: The cross-member (12) comprises first and second beam elements (20, 22) having an open cross-section and firmly secured to each other so as to enclose a closed cross-section chamber (32) having such shape and sizes as to provide the cross-member (12) with the desired torsional stiffness. A free edge (20a) of the first beam element (20) is firmly secured to the outer surface of an intermediate portion (22c) of the second beam element (22) and a free edge (22a) of the second beam element (22) is firmly secured to the inner surface of an intermediate portion (20b) of the first beam element (20). The two beam elements (20, 22) are advantageously made as stamped sheet metal pieces.

Abstract: The arm includes a wheel-side portion for support of a wheel and a body-side portion for connection to the vehicle body, the two arm portions being securely connected to each other by welding. The wheel-side arm portion may be made of cast iron and the body-side arm portion may be made as a steel tubular piece. Alternatively, the wheel-side arm portion is made of cast aluminium and the body-side arm portion is made as an extruded aluminium piece. It is thus possible to combine the high camber stiffness of the wheel-side portion made of cast iron or aluminium with the high compliance in case of impact of the body-side portion made of stamped or extruded steel or aluminium.

Abstract: There is described a motor-vehicle rear suspension comprising a longitudinal arm whose rear end carries the wheel support and whose front end is connected to the motor-vehicle body by a connecting rod, this front end being also connected to an auxiliary arm which is on its turn connected to the motor-vehicle body by means of a connecting-rod. The wheel support is further connected to the motor-vehicle body by means of a transverse linking rod. The longitudinal arm has an intermediate swivel joint and a further articulated arm is provided which connects the wheel support to the motor-vehicle body.