Abstract: The invention provides an apparatus and a method of forming a material of low ductility including providing a first sheet made from a material of low ductility, providing an integrated forming device comprising a heat source and a forming element, and moving the forming element relative to the first sheet along a forming direction while simultaneously heating a localized portion of the first sheet along the forming direction at a substantially constant predetermined distance in front of the forming element. The predetermined distance is selected so as to yield a predetermined temperature to achieve a predetermined ductility at the localized portion of the first sheet when the forming element reaches the localized portion of the first sheet.

Abstract: A vehicular scalable secure gateway system for a vehicle includes a connected gateway and a secure gateway. The vehicular scalable secure gateway system provides flexibility to add and/or remove one or more particular security measures based on the need for the particular security measure or measures.

Abstract: A sensing system for a vehicle includes a plurality of sensors disposed at the vehicle. The plurality of sensors includes individual sensors connected to a vehicle network using a daisy chain topology. A control determines an address of the sensors and calibrates the sensors. The control, responsive to determination that an individual sensor is not the last sensor of a daisy chain of sensors, adjusts the internal electrical configuration to provide an open connection for another sensor. The control, responsive to determination that an individual sensor is the last sensor of the daisy chain of sensors, adjusts the internal electrical configuration to provide a termination configuration. The control, responsive to the outputs of the sensors, determines the presence of one or more objects exterior the vehicle and within the field of sensing of at least one of the sensors.

Abstract: A process for removing a material that is adhered to an underlying surface includes using a laser beam to heat the material to reduce the strength of adhesion between the material and the underlying surface. A stream of gas is directed at the heated material to displace the heated material from the underlying surface.

Abstract: A vision system for a vehicle includes a forward viewing camera disposed at a mirror head of an interior rearview mirror assembly of the vehicle and having a forward field of view through the windshield of the vehicle. A sensor is disposed at the mirror head and determines a change in position of the mirror head relative to a mirror mount of the mirror assembly when the vehicle driver adjusts the mirror head. A control includes a processor operable to process image data captured by the forward viewing camera. Responsive to determination by the sensor of a change of position of the forward viewing camera relative to the mirror mount, the control selects an active sub-array of photosensors to provide an effective field of view of the forward viewing camera. The processor processes image data captured by the active sub-array of photosensors for a driver assistance system of the vehicle.

Abstract: A tool for forming a shaped product has a support body that is fabricated from a first material, such as for instance cast iron. The first material defines a first portion of a forming surface of the tool and has a feature supported thereon. The feature has a layer of a second material that is supported on the first material of the support body, a layer of a third material that is supported on the layer of the second material and a layer of a fourth material that is supported on the layer of the third material. The layer of the fourth material, such as for instance a tool steel alloy, defines a second portion of the forming surface of the tool. During use the first portion of the forming surface and the second portion of the forming surface cooperate to form a desired shape of the shaped product.

Abstract: A system for fabricating a composite article includes a pre-impregnation station for forming a prepreg comprising a reinforcement impregnated with a resin. The prepreg is provided to a blanking station where a blank is cut from the partially cured prepreg and arranged onto a preforming mold. The blank is then transferred to a forming station, and is formed into the composite article using a compression mold. The pre-impregnation station, the blanking station and the forming station are co-located. During forming of the blank into the composite article using the compression mold, additional prepreg is formed in the pre-impregnation station and passes to the blanking station so as to form a next blank for being formed into a next composite article during a subsequent molding cycle. Optionally, the prepreg is partially cured prior to being cut in the blanking station.

Abstract: A vision system for a vehicle includes first and second camera modules disposed at the vehicle so as to have respective first and second fields of view exterior of the vehicle. The first camera module includes a first lens and a first imager, and is operable to capture image data. The second camera module includes a second lens and a second imager, and is operable to capture image data. The first camera module is powered by a first power supply line and the second camera module is powered by a second power supply line. The first camera module includes an image processor operable to process image data captured by the first camera module and the second camera module. The second camera module comprises a second image processor operable to process image data captured by the first camera module and the second camera module.

Abstract: A tool for forming a shaped product has a support body that is fabricated from a first material, such as for instance cast iron. The first material defines a first portion of a forming surface of the tool and has a feature supported thereon. The feature has a layer of a second material that is supported on the first material of the support body, a layer of a third material that is supported on the layer of the second material and a layer of a fourth material that is supported on the layer of the third material. The layer of the fourth material, such as for instance a tool steel alloy, defines a second portion of the forming surface of the tool. During use the first portion of the forming surface and the second portion of the forming surface cooperate to form a desired shape of the shaped product.

Abstract: A method for laser welding first and second components is provided including moving a laser beam across a portion of a surface of the first component at a speed sufficient to generate protuberances on the surface of the first component by means of a humping effect, juxtaposing said first and second components such that opposed surfaces of the first and second components are separated by said protuberances on the surface of the first component, and laser welding said first and second components by scanning the laser beam in a region in which said surfaces are separated by said protuberances. The height of the protuberances can be controlled by controlling a scanning speed of the laser beam.

Abstract: A process for laser-welding pre-coated sheet metal plates comprises loading two pre-coated sheet metal plates at a workstation, such that edges of the plates that are to be welded together are butted against one another. Each plate has a steel substrate and a pre-coat layer, the pre-coat layer including an intermetallic alloy layer and a metallic alloy layer. In a single pass, an area of each plate adjacent to the edges that are butted against one another is irradiated with a defocussed laser beam, thereby melting material of the pre-coat layer within said area of each plate. During the single pass, a stream of a gas is used to blow the melted pre-coat material out of the irradiated areas of the two plates. Absent removing the two plates from the workstation, laser-welding the plates together is performed using a focused laser beam.

Abstract: A process for making a shaped-part from a heat-treatable aluminum alloy blank comprises providing the blank in a hardened temper state, for instance the T6 or another suitable temper state. The as-provided blank is subjected to selective heating, such that a first portion of the blank is heated to a predetermined first temperature for a predetermined first length of time and a second portion of the blank is heated to a predetermined second temperature for a predetermined second length of time. The heated blank is then formed into the desired shape of the shaped-part, and is cooled to ambient temperature. The selective heating substantially increases ductility to facilitate forming of the blank into the desired shape of the shaped part, and provides desired mechanical properties within first and second portions of the shaped part corresponding to the first and second portions of the blank.

Abstract: A method and system for detecting edge cracks of an element of a sheet metal product is provided. The method includes calculating a first stress associated with a forming process employing a first die; calculating a second stress associated with a finishing process employing a second die; combining the first stress and the second stress to formulate a total stress; simulating the sheet metal product to produce a benchmark stress; and comparing the total stress and the benchmark stress to determine if the element predictively contains edge cracks.

Abstract: A sheet metal blank for superplastic forming has, on one side thereof, a first surface region having a coating of a lubricant material of a substantially uniform thickness. The blank also has a second surface region that is one of i) substantially devoid of a coating of the lubricant material and ii) coated with a coating of the lubricant material having a thickness that decreases progressively to a minimum thickness less than the substantially uniform thickness. A third surface region is disposed between the first surface region and the second surface region, the third surface region having a coating of the lubricant material of a thickness that decreases progressively in a direction from the first surface region to the second surface region. In particular, the second surface region is a region of the sheet metal blank that contacts a sharp character line of a forming die during superplastic forming.

Abstract: A process is provided for laser beam welding of surface treated steel components. Two steel components, at least one of which is a surface treated steel component, are relatively arranged to form a joint that is to be welded. Using a laser beam, the two steel components are irradiated along the joint so as to heat materials within each of the two steel components to a welding temperature, and thereby form a weld pool. During welding a metallic constituent is introduced into a leading edge of the weld pool, in front of the laser beam along a welding direction. The introduced metallic constituent combines with a species, which is released into the weld pool from the surface treated steel component, to form a compound that is stable within the weld pool at the welding temperature.

Abstract: The invention is directed to a system and method of applying a coating of lubricant material to the surface of a sheet metal blank in a controlled manner such that some areas of the blank have uniform thickness of lubricant while other areas have no lubricant at all or have a variable amount (progressively increasing or decreasing) of lubricant. This is achieved through the use of a mask template that comprises an overspray fence and at least one contact element. The lubricated coated sheet metal blank is utile for superplastic forming to produce specialized complex shaped parts. The invention advantageously lessens the possibility of skid or slip lines appearing in the finished product as well as lessens the likely build-up of lubricant in forming dies—easing maintenance requirements.

Abstract: An apparatus and method are provided for the simultaneous forming of a plurality of shaped articles from plural sheet metal blanks. First and second sheet metal blanks are arranged between upper and lower forming dies, and a nozzle body having a generally diamond-shaped cross-sectional profile, transverse to an insertion direction, is inserted between the sheet metal blanks. When the forming tool is closed, upper and lower sealing surfaces of the nozzle body press the first and second sheet metal blanks, respectively, against sealing beads that are arranged one each within peripheral areas of the upper and lower forming dies. Opposite side edges of the nozzle body converge one toward the other so as to facilitate forming a seal along each of the side edges of the nozzle body. A pressurized fluid is introduced via the nozzle body for forming the sheet metal blanks within a die cavity.

Abstract: A tool for forming a shaped product has a support body that is fabricated from a first material, such as for instance cast iron. The first material defines a first portion of a forming surface of the tool and has a feature supported thereon. The feature has a layer of a second material that is supported on the first material of the support body, a layer of a third material that is supported on the layer of the second material and a layer of a fourth material that is supported on the layer of the third material. The layer of the fourth material, such as for instance a tool steel alloy, defines a second portion of the forming surface of the tool. During use the first portion of the forming surface and the second portion of the forming surface cooperate to form a desired shape of the shaped product.

Abstract: A forming tool apparatus is provided for forming an article having a negative draft angle that locks the formed article within the forming tool. An insert, which is disposed within a recess defined in a forming surface of the forming tool, has a surface that cooperates with the forming surface of the forming tool to shape a metal blank into a desired final shape. In particular, the surface of the insert is shaped to define the negative draft angle feature of the formed article. Subsequent to forming the article, a linear-drive mechanism is activated to withdraw the insert away from the formed article, and thereby unlock the formed article from the tool. The formed article is then extracted from the tool along an extraction direction that is other than parallel to the direction along which the insert is driven.

Abstract: Warps of a reinforcing filamentary yarn are selectively interwoven with wefts of the reinforcing filamentary yarn, so as to form a tailored woven reinforcement for use in the manufacture of a composite article having a known three-dimensional shape. The wefts extend in a direction transverse to said warps, to form at least one first portion of the woven reinforcement having interwoven warps and wefts, and to form at least one second portion of the woven reinforcement having other than interwoven warps and wefts. The at least one first portion and the at least one second portion are arranged, one relative to the other within said woven reinforcement, in dependence upon the known three-dimensional shape of the composite article. The woven reinforcement is suitable for use in a variety of processes including prepreg processes, Resin Transfer Molding processes and Resin Infusion Molding processes.