Abstract: A method of testing a weld joint includes: preparing a part that includes at least one weld joint which joins at least two metal components with one another; machining at least one hole in the at least one weld joint; inserting, into the at least one port hole, a probe that includes a mirror attached to a camera; and reflecting an image of the weld joint off of the minor and to the camera while the probe is inserted into the at least one port hole. A method of analyzing a weld joint includes: machining a port hole in the weld joint; etching the weld joint; inserting a probe into the port hole, the probe including a minor; reflecting an image of the weld joint off of the mirror towards a camera; capturing the image with the camera; and analyzing the weld joint using the image captured by the camera.

Abstract: A method for producing components by hot forming includes receiving a blank having a patched region and a non-patched region; pre-heating the patched region of the blank in a pre-heat station to a pre-heat temperature by thermal conduction without pre-heating at least a portion of the non-patched region to the pre-heat temperature, to provide a pre-heated blank; transferring the pre-heated blank from the pre-heat station to a furnace; heating the entire blank in the furnace to an austenite temperature, wherein the austenite temperature is higher than the pre-heat temperature; transferring the heated blank from the furnace to a press; and shaping the heated blank in the press.

Abstract: A method for producing components by hot forming comprises (a) heating a first portion and a second portion of a blank in a furnace to a temperature that is below AC3 temperature to provide a heated blank; (b) transferring the heated blank from the furnace to a conductive post-furnace heat station; (c) heating the first portion of the heated blank in the conductive post-furnace heat station to a temperature above the AC3 temperature by thermal conduction to provide a post-heated blank, while the second portion of the heated blank is sufficiently spaced from of the conductive post-furnace heat station so that the second portion of the heated blank is not heated in the conductive post-furnace heat station to the AC3 temperature; (d) transferring the post-heated blank from the conductive post-furnace heat station to a press; and (e) forming the post-heated blank into the shape of the component in the press.

Abstract: A system for producing components by hot forming includes a conductive post-furnace heat station, a furnace, a computer system, and a press. The computer system comprises one or more physical processors operatively connected with the furnace in and the conductive post-furnace heat station. The one or more physical processors being programmed with computer program instructions which, when executed cause the computer system to control the furnace to heat the blank to a temperature that is below AC3 temperature; and control the conductive post-furnace heat station to heat a portion of the heated blank to a temperature above the AC3 temperature by thermal conduction. The press is constructed and arranged to receive the post-heated blank from the post-furnace heat station and to form the post-heated blank into the shape of the component.

Abstract: A method of testing a weld joint includes: preparing a part that includes at least one weld joint which joins at least two metal components with one another; machining at least one hole in the at least one weld joint; inserting, into the at least one port hole, a probe that includes a mirror attached to a camera; and reflecting an image of the weld joint off of the minor and to the camera while the probe is inserted into the at least one port hole. A method of analyzing a weld joint includes: machining a port hole in the weld joint; etching the weld joint; inserting a probe into the port hole, the probe including a minor; reflecting an image of the weld joint off of the mirror towards a camera; capturing the image with the camera; and analyzing the weld joint using the image captured by the camera.

Abstract: A system for producing components by hot forming includes a conductive post-furnace heat station, a furnace, a computer system, and a press. The computer system comprises one or more physical processors operatively connected with the furnace in and the conductive post-furnace heat station. The one or more physical processors being programmed with computer program instructions which, when executed cause the computer system to control the furnace to heat the blank to a temperature that is below AC3 temperature; and control the conductive post-furnace heat station to heat a portion of the heated blank to a temperature above the AC3 temperature by thermal conduction. The press is constructed and arranged to receive the post-heated blank from the post-furnace heat station and to form the post-heated blank into the shape of the component.

Abstract: A localized annealing process and a part having localized areas with increased ductility produced by the process. The part is formed of hard material, tempered, and/or otherwise hardened such that it meets minimum hardness and ductility requirements. The part further includes localized areas that have increased ductility for workability, which could include various types of deformation. The localized annealing process includes providing a part with low levels of ductility and then annealing localized areas of the part for increased ductility that will need to be machined or attached to another formed part. The annealing process includes placing an electrode on either side of the localized area and generating electricity through the localized area. The material in the localized area is then heated from the electricity to form a more ductile physical structure.

Abstract: A system for producing components by hot forming includes a pre-heat station, a furnace, and a press. The pre-heat station is configured to receive a blank; and to pre-heat at least a portion of the blank to a pre-heat temperature by thermal conduction. The furnace is constructed and arranged to receive the pre-heated blank from the pre-heat station and to heat the entire blank to a deformation temperature. The deformation temperature is higher than the pre-heat temperature. The press is constructed and arranged to receive the heated blank from the furnace and to form the heated blank into the shape of the component.

Abstract: A system includes a laser welder and a filler wire feed. The laser welder is configured to weld a workpiece to at least one additional workpiece to form a welded assembly. Each of the workpieces is formed from a steel material and comprises an aluminum based coating thereon. The filler wire feed is configured to feed a filler wire to an interface between the workpieces when the workpieces are being welded to each other to form the welded assembly. The filler wire comprises a composition that includes nickel and chromium. The filler wire is configured to bind with aluminum in the aluminum based coating so as to minimize formation of brittle intermetallics due to mixing of the aluminum in the aluminum based coating with the iron/steel material in the weld joint.

Abstract: A bi-metallic component including a tubular stud member extending from an open first end to an open second end, and a cast member cast around the open second end of the tubular stud member is provided. The cast member is formed from first material, such as an aluminum alloy; and the tubular stud member is formed from a second material, such as steel. The tubular stub member has an interior surface which sealingly receives a removable core member for preventing molten first material from flowing through the stub member between the open ends thereof during casting of the cast member around the second end. The bi-metallic component can be used in a variety of automotive applications, for example in a cradle, frame, twist axle, control arm, door pillar, instrument panel support, or bumper assembly.

Abstract: A bi-metallic component including a tubular stud member extending from an open first end to an open second end, and a cast member cast around the open second end of the tubular stud member is provided. The cast member is formed from first material, such as an aluminum alloy; and the tubular stud member is formed from a second material, such as steel. The tubular stub member has an interior surface which sealingly receives a removable core member for preventing molten first material from flowing through the stub member between the open ends thereof during casting of the cast member around the second end. The bi-metallic component can be used in a variety of automotive applications, for example in a cradle, frame, twist axle, control arm, door pillar, instrument panel support, or bumper assembly.

Abstract: A hybrid torsion beam axle assembly is provided, which includes a steel torsion beam. An end cap is fastened to an end portion of the steel torsion beam, and a cast trailing arm is cast about the end portion of the steel torsion beam including the end cap. In this way, the cast trailing arm is positively and rigidly secured to the steel torsion beam.

Abstract: In one aspect, the invention is directed to a half-cradle for use in a vehicle frame. The half-cradle includes a cast end member formed from a first material and first and second tubular cross-member stubs extending from the cast end member. The first and second tubular cross-member stubs are made from a second material. Each of the stubs has an end buried in the cast end member, wherein the buried end is uncapped. Each of the tubular cross-member stubs has an interior that is configured to sealingly receive a core for use in preventing the filling of the stub with molten first material during casting of the cast end member.

Abstract: A hybrid torsion beam axle assembly is provided, which includes a steel torsion beam. An end cap is fastened to an end portion of the steel torsion beam, and a cast trailing arm is cast about the end portion of the steel torsion beam including the end cap. In this way, the cast trailing arm is positively and rigidly secured to the steel torsion beam.

Abstract: A hybrid torsion beam axle assembly is provided, which includes a steel torsion beam. An end cap is fastened to an end portion of the steel torsion beam, and a cast trailing arm is cast about the end portion of the steel torsion beam including the end cap. In this way, the cast trailing arm is positively and rigidly secured to the steel torsion beam.

Abstract: In one aspect, the invention is directed to a half-cradle for use in a vehicle frame, comprising a cast end member formed from a first material and first and second tubular cross-member stubs extending from the cast end member. The first and second tubular cross-member stubs are made from a second material. Each of the stubs has an end buried in the cast end member, wherein the buried end is uncapped. Each of the tubular cross-member stubs has an interior that is configured to sealingly receive a core for use in preventing the filling of the stub with molten first material during casting of the cast end member.

Abstract: A hybrid torsion beam axle assembly is provided, which includes a steel torsion beam. An end cap is fastened to an end portion of the steel torsion beam, and a cast trailing arm is cast about the end portion of the steel torsion beam including the end cap. In this way, the cast trailing arm is positively and rigidly secured to the steel torsion beam.