Abstract: A vehicle frame includes a first beam with a first wall and a second wall extended in a first beam longitudinal direction, wherein the first wall and the second wall are spaced from each other in a first beam transverse direction substantially perpendicular to the first beam longitudinal direction. The first beam includes at least one first beam reinforcement structure, the at least one first beam reinforcement structure including a first leg and a second leg disposed along the first beam and extended between the first wall and the second wall in the first beam transverse direction. The first leg and the second leg are angled toward each other along the first beam transverse direction from the second wall toward the first wall.

Abstract: A vehicle door beam and related methods of making door beams include a flat-rolled aluminum alloy sheet, where two edges of the sheet that are transverse to the roll direction of the sheet are brought together to form a tube. The two edges are friction stir welded together to form a butt joint along a length of the tube. The tube is arranged, along with other optional components, as a side-impact door beam in a vehicle door, such that the butt joint is facing away from an expected impact direction of the vehicle door.

Abstract: A vehicle frame structural member assembly method includes an elongated frame member and a reinforcement member. The reinforcement member is complementarily arranged adjacent the elongated frame member.

Abstract: A vehicle frame includes a first beam with a first wall and a second wall extended in a first beam longitudinal direction, wherein the first wall and the second wall are spaced from each other in a first beam transverse direction substantially perpendicular to the first beam longitudinal direction. The first beam includes at least one first beam reinforcement structure, the at least one first beam reinforcement structure including a first leg and a second leg disposed along the first beam and extended between the first wall and the second wall in the first beam transverse direction. The first leg and the second leg are angled toward each other along the first beam transverse direction from the second wall toward the first wall.

Abstract: A vehicle body includes a structural member having an inner surface defining an elongated cavity. The structural member includes an outer panel member joined to an inner panel member. A tension web secured in the cavity separates the outer and inner panel members. A reinforcement member is positioned in the cavity of the structural member. The reinforcement member contacts the transverse web and a gap is provided between the reinforcement member and the inner surface of the structural member. The reinforcement member including a base member having a plurality of bumpers extended in a width direction of the reinforcement member. The plurality of bumpers face one of the inner surface and the tension web. An adhesive secured to the reinforcement member is activatable to expand toward the inner surface to define a joint between the reinforcement member and the structural member and to at least partially fill the gap.

Abstract: A fabric processing method and component (e.g., a vehicle component) includes providing and/or arranging a first fabric charge and a second fabric charge. A multi-piece fabric assembly is formed for single stage draping by stitching together the first and second fabric charges along a neutral stitching path. The multi-piece fabric assembly is formed into a three-dimensional shape and is then impregnated with a polymeric material to form the component.

Abstract: A method of making a roof assembly includes bringing first and second adhesive beads into contact with a roof panel and a roof stiffener to thereby define a chamber. The first adhesive bead forms a continuous perimeter around a first vacuum aperture in the roof stiffener to thereby define a first vacuum chamber. The second adhesive bead defines a second continuous perimeter around a second vacuum aperture in the roof stiffener to thereby define a second vacuum chamber. A vacuum is created in each of the first and second vacuum chambers. An outer periphery of each of the first and second adhesive beads is in direct fluid communication with the surrounding atmosphere through a perimeter opening of the chamber.

Abstract: A vehicle frame construction and method includes an elongated hollow frame member having a plurality of interior sides and a reinforcement member. The reinforcement member is formed from a thermoplastic polymer and is installed so as to be arranged within the elongated hollow frame member to reinforce each interior side of the elongated hollow frame member in a plane orthogonally oriented relative to a longitudinal axis of the elongated hollow frame member.

Abstract: A method of assembling at least two types of vehicles with different powertrain requirements on the same assembly line is provided. The method includes assembling a first structural body component for a first vehicle type including a first powertrain requirement. The first structural body component comprises a first structural core surrounded by a first fiber reinforced material having a first thickness. The first structural body component has a first external geometry. The method includes assembling a second structural body component for a second vehicle type that has a second powertrain requirement different from the first powertrain requirement. The second structural body component comprises a second structural core surrounded by a second fiber reinforced material having a second thickness different from the first thickness. The second structural body component has a second external geometry that is the same in shape and dimension as the first external geometry.

Abstract: A method of joining first and second vehicle components to make an assembly includes applying structural adhesive and mastic to the first component. The first and second component may be made of different metals, and are brought together and joined at an interface using a linkage. Thereafter, the structural adhesive and mastic are cured. The mastic seals an interior edge of the interface, which is located at an interior of the assembly. A dust sealer is applied and cured to seal the exterior edge of the interface, which is located at an exterior of the assembly. The method results in sealing of all the edges around the entire perimeter of the interface, thus inhibiting water intrusion into the interface and possible corrosion resulting therefrom.

Abstract: A vehicle frame structural member assembly method includes an elongated frame member and a reinforcement member. The reinforcement member is complementarily arranged adjacent the elongated frame member.

Abstract: A method of joining first and second vehicle components to make an assembly includes applying structural adhesive and mastic to the first component. The first and second component may be made of different metals, and are brought together and joined at an interface using a linkage. Thereafter, the structural adhesive and mastic are cured. The mastic seals an interior edge of the interface, which is located at an interior of the assembly. A dust sealer is applied and cured to seal the exterior edge of the interface, which is located at an exterior of the assembly. The method results in sealing of all the edges around the entire perimeter of the interface, thus inhibiting water intrusion into the interface and possible corrosion resulting therefrom.

Abstract: A vehicle frame structural member assembly method includes an elongated frame member and a reinforcement member. The reinforcement member is complementarily arranged adjacent the elongated frame member.

Abstract: A vehicle door beam and related methods of making door beams include a flat-rolled aluminum alloy sheet, where two edges of the sheet that are transverse to the roll direction of the sheet are brought together to form a tube. The two edges are friction stir welded together to form a butt joint along a length of the tube. The tube is arranged, along with other optional components, as a side-impact door beam in a vehicle door, such that the butt joint is facing away from an expected impact direction of the vehicle door.

Abstract: A method of assembling at least two types of vehicles with different powertrain requirements on the same assembly line is provided. The method includes assembling a first structural body component for a first vehicle type including a first powertrain requirement. The first structural body component comprises a first structural core surrounded by a first fiber reinforced material having a first thickness. The first structural body component has a first external geometry. The method includes assembling a second structural body component for a second vehicle type that has a second powertrain requirement different from the first powertrain requirement. The second structural body component comprises a second structural core surrounded by a second fiber reinforced material having a second thickness different from the first thickness. The second structural body component has a second external geometry that is the same in shape and dimension as the first external geometry.

Abstract: A vehicle body includes a structural member having an inner surface defining an elongated cavity. The structural member includes an outer panel member joined to an inner panel member. A tension web secured in the cavity separates the outer and inner panel members. A reinforcement member is positioned in the cavity of the structural member. The reinforcement member contacts the transverse web and a gap is provided between the reinforcement member and the inner surface of the structural member. The reinforcement member including a base member having a plurality of bumpers extended in a width direction of the reinforcement member. The plurality of bumpers face one of the inner surface and the tension web. An adhesive secured to the reinforcement member is activatable to expand toward the inner surface to define a joint between the reinforcement member and the structural member and to at least partially fill the gap.

Abstract: A vehicle body includes a structural member having an inner surface defining an elongated cavity. The structural member includes an outer panel member joined to an inner panel member. A reinforcement member is positioned in the cavity wherein a gap is provided between the reinforcement member and the inner surface of the structural member. The reinforcement member includes an outer section, an inner section and a tension web interposed between and contacting the outer section and inner section. The outer section faces the outer panel member and the inner section faces the inner panel member. The tension web is secured to the outer panel member and inner panel member. An adhesive secured to the reinforcement member is activatable to expand toward the inner surface of the structural member to define a joint between the reinforcement member and the structural member and to at least partially fill the gap.

Abstract: A vehicle frame construction and method includes an elongated hollow frame member having a plurality of interior sides and a reinforcement member. The reinforcement member is formed from a thermoplastic polymer and is installed so as to be arranged within the elongated hollow frame member to reinforce each interior side of the elongated hollow frame member in a plane orthogonally oriented relative to a longitudinal axis of the elongated hollow frame member.

Abstract: A vehicle frame construction and method includes an elongated hollow frame member having a plurality of interior sides and a reinforcement member. The reinforcement member is formed from a thermoplastic polymer and is installed so as to be arranged within the elongated hollow frame member to reinforce each interior side of the elongated hollow frame member in a plane orthogonally oriented relative to a longitudinal axis of the elongated hollow frame member.

Abstract: A friction stir welding tool and method for forming a friction stir weld joint includes a rotatable body having a rotatable shoulder for maintaining surface contact and maintaining plunge depth and a rotatable pin extending from the rotatable shoulder. The rotatable pin is integrally formed with the rotatable shoulder. The tool further includes a stationary body annularly disposed around the rotatable body. The stationary body has a stationary shoulder annularly disposed around the rotatable shoulder for further maintaining surface contact and managing plunge depth.