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 process for localized hardening of steel sheet components includes scanning a laser beam in a scan direction across a predetermined portion of the steel sheet component. The laser beam selectively heats material within the predetermined portion of the steel sheet component to a temperature of austenitizing transformation. During scanning of the laser beam across the predetermined portion, a source of external cooling is applied to the material within the predetermined portion and immediately behind the laser beam along the scan direction of the laser beam. The source of external cooling is selected to cool the material at a sufficiently rapid rate to form a locally hardened region that is defined substantially within the predetermined portion. Subsequent to applying the source of external cooling, the material within the predetermined portion of the steel sheet component is allowed to cool to ambient temperature.

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: A hot forming die that includes a first die and a second die. The first die has a first die structure that is formed of a tool steel. The first die structure has a first die surface and a plurality of first cooling apertures. The first die surface has a complex shape. The first cooling apertures are spaced apart from the die surface by a first predetermined distance. The second die has a second die surface. The first and second die surfaces cooperate to form a die cavity. Related methods for forming a hot forming die and for hot forming a workpiece are also provided.

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 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 a 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: 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: 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 hot forming die that includes a first die and a second die. The first die has a first die structure that is formed of a tool steel. The first die structure has a first die surface and a plurality of first cooling apertures. The first die surface has a complex shape. The first cooling apertures are spaced apart from the die surface by a first predetermined distance. The second die has a second die surface. The first and second die surfaces cooperate to form a die cavity. Related methods for forming a hot forming die and for hot forming a workpiece are also provided.

Abstract: A hot forming die that includes a first die and a second die. The first die has a first die structure that is formed of a tool steel. The first die structure has a first die surface and a plurality of first cooling apertures. The first die surface has a complex shape. The first cooling apertures are spaced apart from the die surface by a first predetermined distance. The second die has a second die surface. The first and second die surfaces cooperate to form a die cavity. Related methods for forming a hot forming die and for hot forming a workpiece are also provided.

Abstract: A hot forming die that includes a first die and a second die. The first die has a first die structure that is formed of a tool steel. The first die structure has a first die surface and a plurality of first cooling apertures. The first die surface has a complex shape. The first cooling apertures are spaced apart from the die surface by a first predetermined distance. The second die has a second die surface. The first and second die surfaces cooperate to form a die cavity. Related methods for forming a hot forming die and for hot forming a workpiece are also provided.