Abstract: A vehicle chassis having substantially all of the mechanical, electrical, and structural componentry necessary for a fully functional vehicle, including at least an energy conversion system, a steering system, and a braking system. The chassis is configured for matability with a variety of different types or styles of vehicle bodies. Various prior art mechanical control linkages between a driver and controlled systems are replaced with non-mechanical control signal transmission components. Fuel cell technology is also implemented. A quick plastic formed (QPF) engineered body floorpan includes formations thereon to provide structural integrity to support body components and acts as an assembly aid. The body floorpan is formed from a single aluminum alloy sheet.

Abstract: A vehicle chassis having substantially all of the mechanical, electrical, and structural componentry necessary for a fully functional vehicle includes at least an energy conversion system, a steering system, and a braking system. The chassis is configured for matability with a variety of different types or styles of vehicle bodies. Various prior art mechanical control linkages between a driver and controlled systems are replaced with non-mechanical control signal transmission components. Fuel cell technology is also implemented. A quick plastic formed (QPF) rigid sheet (belly pan) includes cavities formed therein to facilitate attachment of various components of the energy conversion system, energy storage system, braking system, steering system, etc.

Abstract: A method of stretch forming an aluminum metal sheet that includes the steps of placing an aluminum metal sheet in a hot forming tool, forming a shaped part at an elevated temperature, removing the hot shaped part from the forming tool, and thereafter transferring the hot shaped part to a cooling fixture. The transfer and removal steps are performed at a speed that is variable based on a correlation of the temperature and strength of the aluminum metal sheet and the speed at which the hot shaped part may be transferred without distortion of its shape due to inertia.

Abstract: A method of stretch forming an aluminum metal sheet that includes the steps of placing an aluminum metal sheet in a hot forming tool, forming a shaped part at an elevated temperature, removing the hot shaped part from the forming tool, and thereafter transferring the hot shaped part to a cooling fixture. The transfer and removal steps are performed at a speed that is variable based on a correlation of the temperature and strength of the aluminum metal sheet and the speed at which the hot shaped part may be transferred without distortion of its shape due to inertia.

Abstract: Superplastic forming of sheet metal blanks is advanced both is quantity and quality with the utilization of a part separating and pressure distributing mid plate sandwiched between a pair of blanks. This arrangement is loaded between upper and lower die halves operatively mounted in a heated press which closes to effect the piercing of one of the blanks by a nozzle which subsequently delivers pressurized air or other inert gas to an intermediate chamber formed by the mid plate between the blanks to effect the simlayaneously forming of separate parts in both forming dies.

Abstract: Superplastic forming of sheet metal blanks is advanced both is quantity and quality with the utilization of a part separating and pressure distributing mid plate sandwiched between a pair of blanks. This arrangement is loaded between upper and lower die halves operatively mounted in a heated press which closes to effect the piercing of one of the blanks by a nozzle which subsequently delivers pressurized air or other inert gas to an intermediate chamber formed by the mid plate between the blanks to effect the simlayaneously forming of separate parts in both forming dies.

Abstract: A vehicle chassis having substantially all of the mechanical, electrical, and structural componentry necessary for a fully functional vehicle includes at least an energy conversion system, a steering system, and a braking system. The chassis is configured for matability with a variety of different types or styles of vehicle bodies. Various prior art mechanical control linkages between a driver and controlled systems are replaced with non-mechanical control signal transmission components. Fuel cell technology is also implemented. A quick plastic formed (QPF) rigid sheet (belly pan) includes cavities formed therein to facilitate attachment of various components of the energy conversion system, energy storage system, braking system, steering system, etc.

Abstract: A vehicle chassis having substantially all of the mechanical, electrical, and structural componentry necessary for a fully functional vehicle, including at least an energy conversion system, a steering system, and a braking system. The chassis is configured for matability with a variety of different types or styles of vehicle bodies. Various prior art mechanical control linkages between a driver and controlled systems are replaced with non-mechanical control signal transmission components. Fuel cell technology is also implemented. A quick plastic formed (QPF) engineered body floorpan includes formations thereon to provide structural integrity to support body components and acts as an assembly aid. The body floorpan is formed from a single aluminum alloy sheet.

Abstract: Equipment and methods for the rapid and easy cleaning of metal forming dies while in a press and operating at elevated temperatures. The invention features the physical removal of excess lubricant collecting on the hot surface of the forming dies under operating conditions so that no lubricant-induced flaws occur on the show surface of the formed part for optimized production of high quality parts. Special and effector tooling is supplied with high velocity air which draws in solid CO2 which sublimes into pressurize streams of gaseous CO2 that is discharged through nozzles onto the forming surfaces of hot forming dies after a number of lubricated parts have been formed therewith to physically sweep foreign matter including lubricants from the die surfaces. A robot is employed to move the activated end effector in predetermined paths across the dies for fully sweeping and cleaning the forming surfaces. The gas then dissipates.

Abstract: Equipment and methods for the rapid and easy cleaning of metal forming dies while in a press and operating at elevated temperatures. The invention features the physical removal of excess lubricant collecting on the hot surface of the forming dies under operating conditions so that no lubricant-induced flaws occur on the show surface of the formed part for optimized production of high quality parts. Special and effector tooling is supplied with high velocity air which draws in solid CO2 which sublimes into pressurize streams of gaseous CO2 that is discharged through nozzles onto the forming surfaces of hot forming dies after a number of lubricated parts have been formed therewith to physically sweep foreign matter including lubricants from the die surfaces. A robot is employed to move the activated end effector in predetermined paths across the dies for fully sweeping and cleaning the forming surfaces. The gas then dissipates.

Abstract: A method is disclosed for stretching magnesium-containing aluminum alloy sheet stock into intricate shapes such as are required in automotive body panels. The sheet stock, at a temperature in the range of about 400° C. to about 510° C., is stretched under the pressure of a working gas into conformance with the surface of a forming tool. The sheet forming pressure is increased continually in a controlled manner from ambient pressure to a final forming level in the range of about 250 psi to about 500 psi or higher. A portion of the sheet can experience strain rates substantially higher than 10−3 sec−1 and the forming of the sheet can be completed within 12 minutes.

Abstract: A method is disclosed for stretching sheet blanks, especially superplastic sheets, by differential gas pressure into conformity with a female die surface without encountering excessive thinning or tearing of the sheet. The warmed SPF sheet is draped over a preformed surface to draw more of the sheet material into the die cavity before the edges of the sheet are fixedly clamped whereby the additional formable material is used in forming the product, thereby reducing thinning and tears.

Abstract: An improved method of forming a severe bend or a hem in a sheet of wrought aluminum age-hardened and age-hardenable alloy includes heating the region to be bent or hemmed to a temperature above about 250.degree. C. for a period of seconds and then quenching the heated region to remove the age-hardening effect and thereafter accomplishing the bend or hem before age hardening of the heated region occurs.