Abstract: A first method is disclosed for forming a tubular reinforcement that comprises the steps of: providing a 7xxx aluminum tube, heating tube to at least 450° C. and water quenching the tube in less than or equal to 20 seconds after heating. All of the forming processes on the tube are then completed from within 1 to 8 hours of quenching. A second method for forming a tubular reinforcement is disclosed that comprises the steps of providing a 7xxx-O temper aluminum tube and forming the tube into a predetermined shape. The tube in then heated the tube to at least 450° C. and quenched the tube with water or air in a hydroforming die just prior to or while hydroforming the tube.

Abstract: A method is disclosed for forming an aluminum alloy vehicle body component. An aluminum alloy billet is extruded into an aluminum tube that includes longitudinal weld seams formed in a sidewall of the tube during extrusion. A weld seam locating pip is also formed on a sidewall of the tube during extrusion. The pip is used to locate the weld seams during manufacturing of the body component.

Abstract: A method and a system are disclosed for making an article of manufacture from a blank defining an internal opening. A stack of blanks are aligned and the internal openings of the blanks in the stack of blanks are machined by a rotary cutting tool to a finished dimension. The blanks are clamped together before machining in a numerically controlled machine tool. The blanks are subsequently formed individually in a sheet metal forming operation in which the inner perimeter of the internal openings is expanded as the blank is formed.

Abstract: A method and a system are disclosed for making an article of manufacture from a blank defining an internal opening. A stack of blanks are aligned and the internal openings of the blanks in the stack of blanks are machined by a rotary cutting tool to a finished dimension. The blanks are clamped together before machining in a numerically controlled machine tool. The blanks are subsequently formed individually in a sheet metal forming operation in which the inner perimeter of the internal openings is expanded as the blank is formed.

Abstract: A system and method for applying a marking to a part in a stamping die is provided by the present disclosure. The system includes a mechanical application device having a controlled volume of a marking medium that is coupled to movement of the stamping die. In one form, the controlled volume of the marking medium is not regulated by either an external pneumatic source of an external electrical source.

Abstract: A value stream process or method for forming vehicle rails from extruded aluminum tubes includes the steps of extruding an aluminum tube and hydroforming the extruded aluminum tube into a vehicle rail. More specifically, the method includes extruding the aluminum tube, bending the aluminum tube, preforming the aluminum tube, hydroforming the aluminum tube into a vehicle rail, trimming the vehicle rail to length and then artificially aging the rail followed by batch chemical pretreatment. In an alternative embodiment the artificial aging and batch chemical pretreatment processes are performed in reverse order. In either of the embodiments, localized induction annealing to recover formability may be performed between bending and preforming, between preforming and hydroforming or both.

Abstract: A first method is disclosed for forming a tubular reinforcement that comprises the steps of: providing a 7xxx aluminum tube, heating tube to at least 450° C. and water quenching the tube in less than or equal to 20 seconds after heating. All of the forming processes on the tube are then completed from within 1 to 8 hours of quenching. A second method for forming a tubular reinforcement is disclosed that comprises the steps of providing a 7xxx-O temper aluminum tube and forming the tube into a predetermined shape. The tube in then heated the tube to at least 450° C. and quenched the tube with water or air in a hydroforming die just prior to or while hydroforming the tube.

Abstract: A stamping die is provided. The stamping die includes a die block, a punch, and a trap wall. The punch is configured to engage the die block in order to form a part from a sheet metal blank. The trap wall is secured to the punch and configured to restrict the flow of sheet metal into the die block during punch and die block engagement. The trap wall is adjustable with respect to the punch such that a trap wall adjustment alters the flow of sheet metal into the die block.

Abstract: A galling-resistive insert is positioned on an outer surface of a mandrel assembly. The insert is secured at the outer surface of the mandrel assembly and functions to reduce galling of an inner surface of a tubular blank during a rotary-draw bending operation.

Abstract: A method and a system are disclosed for making an article of manufacture from a blank defining an internal opening. A stack of blanks are aligned and the internal openings of the blanks in the stack of blanks are machined by a rotary cutting tool to a finished dimension. The blanks are clamped together before machining in a numerically controlled machine tool. The blanks are subsequently formed individually in a sheet metal forming operation in which the inner perimeter of the internal openings is expanded as the blank is formed.

Abstract: A method of recovery heat treatment of a workpiece includes contacting at least a portion of the workpiece with a fluid heated to a temperature sufficient to heat the at least a portion of the workpiece to a predetermined temperature range in a predetermined time period. The method may be implemented as a first step of a two-stage recovery heat treatment or annealing process, followed by a second step of heating the at least a portion of the workpiece to a final target temperature by another annealing process.

Abstract: In at least one embodiment, a metal blank is provided including a metal sheet having a surface including at least one pair of channels defined therein. Each channel may have a first portion extending from an edge of the blank and a second portion in an interior of the blank. The second portion may be wider than the first portion. The blank may include at least one pair of thermocouple wires, with one wire being attached to each second portion. An adhesive material may be disposed in each second portion. The wires may be attached by welding and the adhesive material may be a metallic composite adhesive. The disclosed blank may be used to calibrate or otherwise assess a process where the blank is being heated or cooled, such as aluminum hot-stamping.

Abstract: A method of producing a laminated article comprising placing a first metal skin, a core, and a second metal skin freely onto each other as discreet layers to provide a layered component; and forming the layered component into a shaped article via a die prior to producing a laminated article by applying pressure and heat to the shaped article, wherein at least the first skin moves relative to the core and/or second skin during the forming.

Abstract: A method is disclosed for forming an aluminum alloy vehicle body component. An aluminum alloy billet is extruded into an aluminum tube that includes longitudinal weld seams formed in a sidewall of the tube during extrusion. A weld seam locating pip is also formed on a sidewall of the tube during extrusion. The pip is used to locate the weld seams during manufacturing of the body component.

Abstract: A stamping die is provided. The stamping die includes a die block, a punch, and a trap wall. The punch is configured to engage the die block in order to form a part from a sheet metal blank. The trap wall is secured to the punch and configured to restrict the flow of sheet metal into the die block during punch and die block engagement. The trap wall is adjustable with respect to the punch such that a trap wall adjustment alters the flow of sheet metal into the die block.

Abstract: A method of hydroforming a vehicle rail from an extruded aluminum tube includes the steps of positioning the extruded aluminum tube into a hydroforming die and partially closing the hydroforming die. Next is the step of applying a liquid under a first level of pressure to the extruded aluminum tube in the hydroforming die. This is followed by engaging an inner radius of a bend in the extruded aluminum tube with the hydroforming die before completely closing the hydroforming die and increasing the level of liquid pressure in the workpiece to a second level to form and hydro-pierce a part from the extruded aluminum tube.

Abstract: An extruded aluminum alloy tube for hydroforming into an automotive body component includes a wall defining a closed perimeter. The wall includes weld seams disposed in the wall and running longitudinally along the tube. An extruded pip is disposed on the wall and runs longitudinally along the tube. The pip is parallel to the seams and is configured to identify a location of the seams for alignment of the tube during manufacturing.

Abstract: In at least one embodiment, a metal blank is provided including a metal sheet having a surface including at least one pair of channels defined therein. Each channel may have a first portion extending from an edge of the blank and a second portion in an interior of the blank. The second portion may be wider than the first portion. The blank may include at least one pair of thermocouple wires, with one wire being attached to each second portion. An adhesive material may be disposed in each second portion. The wires may be attached by welding and the adhesive material may be a metallic composite adhesive. The disclosed blank may be used to calibrate or otherwise assess a process where the blank is being heated or cooled, such as aluminum hot-stamping.

Abstract: A method and tool for calibrating an extruded tube for use in a manufacturing operation. According to the method, the tube is stretched while in a clamping tool by approximately 3%. The tool encloses the tube while a stretching mechanism is clamped to opposite longitudinal ends of the tube and applies a stretching force to opposite ends of the tube. The tool includes a clamping mechanism that clamps the tube into a cavity and a stretching mechanism with clamps that are attached to opposite longitudinal ends of the tube to calibrate the tube by longitudinally stretching the tube.

Abstract: A value stream process or method for forming vehicle rails from extruded aluminum tubes includes the steps of extruding an aluminum tube and hydroforming the extruded aluminum tube into a vehicle rail. More specifically, the method includes extruding the aluminum tube, bending the aluminum tube, preforming the aluminum tube, hydroforming the aluminum tube into a vehicle rail, trimming the vehicle rail to length and then artificially aging the rail followed by batch chemical pretreatment. In an alternative embodiment the artificial aging and batch chemical pretreatment processes are performed in reverse order. In either of the embodiments, localized induction annealing to recover formability may be performed between bending and preforming, between preforming and hydroforming or both.