Abstract: A header beam couples between A-pillars of a vehicle frame. The header beam is formed from a generally straight beam segment that is extruded to have a hollow body portion with supportive legs extending within the hollow interior along the length of the beam segment, defining uninterrupted forward and rearward box sections for supporting continuous load paths on the header beam. The end portions of the beam segment are clamped and the beam segment is stretch bent to form a curvature between the end portions that remain generally straight. A front flange extends forward along the body portion and is struck proximate the end portions to form an edge that is parallel to the curvature formed between the end portions. The end portions are attached to the A-pillars and the edge of the front flange is attached to a windshield.

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 reinforcement received between facing surfaces of adjacent panels that may be part of a hinge pillar of a vehicle such as a pickup truck and the panels may be aluminum. The reinforcement may be a one-piece molded structure. The reinforcement includes ribs that extend between the facing surfaces in a lattice arrangement defining a plurality of cells. The cells may have a number of transverse walls defining a perimeter of a polygon. The polygonal cells may have a facing wall on one side of the cell closing the cell. The facing wall may have an adhesive that is applied to the reinforcement and expanded in a paint bake oven to secure the reinforcement to the adjacent panels.

Abstract: A hydro-formed body side rail is assembled by a bracket to a front header. The front header is an extruded cross-car structural support that is joined to the body side rail by a framed joint. A gap is defined between the body side outer panel and the hydro-formed side rail relative to a lateral end of a front header. Side impact test loads are applied initially to the body side rail and compress the bracket. Compression of the bracket closes the gap and the impact loads are applied to the cross-car structural support.

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: 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: A header beam couples between A-pillars of a vehicle frame. The header beam is formed from a generally straight beam segment that is extruded to have a hollow body portion with supportive legs extending within the hollow interior along the length of the beam segment, defining uninterrupted forward and rearward box sections for supporting continuous load paths on the header beam. The end portions of the beam segment are clamped and the beam segment is stretch bent to form a curvature between the end portions that remain generally straight. A front flange extends forward along the body portion and is struck proximate the end portions to form an edge that is parallel to the curvature formed between the end portions. The end portions are attached to the A-pillars and the edge of the front flange is attached to a windshield.

Abstract: A frame component of a vehicle, such as a header beam that couples between the A-pillars of a vehicle frame, includes an extruded hollow member having top and bottom exterior walls and side walls that together enclose an elongated internal volume of the hollow member. A pair of interior walls extends along the internal volume separating outer load sections adjacent to the side walls from a central attachment section. The outer load sections are void of apertures for supporting continuous load paths. A formation on the bottom exterior wall protrudes into the internal volume in the central attachment section. The formation includes an inset surface angled, located, and otherwise configured for attaching a subassembly to the frame component.

Abstract: A frame component of a vehicle, such as a header beam that couples between the A-pillars of a vehicle frame, includes an extruded hollow member having top and bottom exterior walls and side walls that together enclose an elongated internal volume of the hollow member. A pair of interior walls extends along the internal volume separating outer load sections adjacent to the side walls from a central attachment section. The outer load sections are void of apertures for supporting continuous load paths. A formation on the bottom exterior wall protrudes into the internal volume in the central attachment section. The formation includes an inset surface angled, located, and otherwise configured for attaching a subassembly to the frame component.

Abstract: A modular body structure and a method for assembling a body structure in a vehicle includes fitting a pillar having first and second ends between a roof rail and a lower support such that the first end is disposed below a top of the roof rail. The pillar is fastened to the roof rail and the lower support with first threaded fasteners by friction drilling holes through the pillar and the roof rail and the lower support.

Abstract: A vehicle front end structure includes a hinge pillar having laterally spaced first and second vertical mounting surfaces that extend in a longitudinal direction. The vehicle also includes a tubular support member having a first wall secured to the first vertical mounting surface and a second wall secured to the second vertical mounting surface. The second wall extends rearward of the first wall and is secured to the hinge pillar laterally outboard of the first wall. A notched portion through at least one horizontal wall interconnecting the first and second walls of the tubular support may operate as a buckling location of the tubular support.

Abstract: A body structure for a vehicle includes a cowl side defining a first vertical and longitudinal plane. A hinge pillar including a tab portion is attached to the cowl side in the first plane. The hinge pillar includes a stepped surface defining a second vertical and longitudinal plane that is offset outwardly from the first plane and parallel to the first plane. A front end rail includes an inner sidewall fastened to the cowl side and an outer sidewall fastened to the stepped surface the stepped surface. The longitudinal loads applied to the front end rail are transferred in shear to the hinge pillar and cowl side.

Abstract: A header beam couples between A-pillars of a vehicle frame. The header beam is formed from a generally straight beam segment that is extruded to have a hollow body portion with supportive legs extending within the hollow interior along the length of the beam segment, defining uninterrupted forward and rearward box sections for supporting continuous load paths on the header beam. The end portions of the beam segment are clamped and the beam segment is stretch bent to form a curvature between the end portions that remain generally straight. A front flange extends forward along the body portion and is struck proximate the end portions to form an edge that is parallel to the curvature formed between the end portions. The end portions are attached to the A-pillars and the edge of the front flange is attached to a windshield.

Abstract: A frame component of a vehicle, such as a header beam that couples between the A-pillars of a vehicle frame, includes an extruded hollow member having top and bottom exterior walls and side walls that together enclose an elongated internal volume of the hollow member. A pair of interior walls extends along the internal volume separating outer load sections adjacent to the side walls from a central attachment section. The outer load sections are void of apertures for supporting continuous load paths. A formation on the bottom exterior wall protrudes into the internal volume in the central attachment section. The formation includes an inset surface angled, located, and otherwise configured for attaching a subassembly to the frame component.

Abstract: A header beam couples between A-pillars of a vehicle frame. The header beam is formed from a generally straight beam segment that is extruded to have a hollow body portion with supportive legs extending within the hollow interior along the length of the beam segment, defining uninterrupted forward and rearward box sections for supporting continuous load paths on the header beam. The end portions of the beam segment are clamped and the beam segment is stretch bent to form a curvature between the end portions that remain generally straight. A front flange extends forward along the body portion and is struck proximate the end portions to form an edge that is parallel to the curvature formed between the end portions. The end portions are attached to the A-pillars and the edge of the front flange is attached to a windshield.

Abstract: A header beam couples between A-pillars of a vehicle frame. The header beam is formed from a generally straight beam segment that is extruded to have a hollow body portion with supportive legs extending within the hollow interior along the length of the beam segment, defining uninterrupted forward and rearward box sections for supporting continuous load paths on the header beam. The end portions of the beam segment are clamped and the beam segment is stretch bent to form a curvature between the end portions that remain generally straight. A front flange extends forward along the body portion and is struck proximate the end portions to form an edge that is parallel to the curvature formed between the end portions. The end portions are attached to the A-pillars and the edge of the front flange is attached to a windshield.

Abstract: A panel incorporated into a pillar of a vehicle body includes a base portion defining an opening, and a flange extending from an edge of the opening such that a portion of the flange forms an acute angle with the base portion.

Abstract: A panel incorporated into a pillar of a vehicle body includes a base portion defining an opening, and a flange extending from an edge of the opening such that a portion of the flange forms an acute angle with the base portion.

Abstract: This invention relates to a lubricating oil composition comprising a base stock and an antioxidant comprising an oil soluble trinuclear organomolybdenum compound of the generic formula: Mo3Sx—(Q) (1) wherein x is from 4 to 10 and Q is a core group, which may be a ligand, and at least one other compound selected from a phenolic and an aminic compound wherein the basestock has a kinematic viscosity at 100° C. (KV100) from about 2 cSt to 20 cSt (2×10−6 to 20×10−6 m2/sec) and a saturates content of at least 85%. The composition has a high oxidation stability, reduced deposit formation and is capable of giving rise to good fuel economy improvement.

Abstract: This invention relates to a lubricating oil composition comprising a base stock and an antioxidant comprising an oil soluble trinuclear organomolybdenum compound of the generic formula: Mo3Sx-(Q) (I) wherein x is from 4 to 10 and Q is a core group, which may be a ligand, and at least one other compound selected from a phenolic and an aminic compound wherein the basestock has a kinematic viscosity at 100° C. (KV100) from about 2 cSt to 20 cSt (2×10−6 to 20×10−6 m2/sec) and a saturates content of at least 85%. The composition has a high oxidation stability, reduced deposit formation and is capable of giving rise to good fuel economy improvement.