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.

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 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 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 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 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 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 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 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 method of single-sided resistance welding includes providing a first workpiece and a second workpiece. The first workpiece is positioned so that at least a portion of the first workpiece is in contact with at least a portion of the second workpiece. A weld electrode is positioned in contact with the first workpiece, and a ground electrode is positioned in contact with the second workpiece. A determination is made as to whether a gap or other high resistance condition is present between the first workpiece and the second workpiece. If a gap or other high resistance condition is determined to be present between the first workpiece and the second workpiece, the gap or other high resistance condition is reduced, and the first workpiece and the second workpiece are joined through welding.

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 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 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 multi-material joint includes first and second body members, a staple, a wire ladder, and an adhesive. The first body member includes a first layer of fiber reinforced material which has first upper and lower surfaces. The second body member includes a metal. The staple includes first and second prongs joined by a crown. The first and second prongs are inserted through the first layer such that the crown is positioned adjacent to the first upper surface. The wire ladder is positioned adjacent to the first lower surface and includes first and second rails coupled together by a plurality of rungs. The first and second prongs hook over the respective first and second rungs. The adhesive is positioned between the first and second body members, and covers at least a portion of the crown. Other multi-material joints are also provided, as are methods of making multi-material joints.

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.

Abstract: A vehicle frame assembly, system and method includes a vehicle frame assembly having a variable length longitudinal frame component. The longitudinal frame component is formed at a first length when used on a first vehicle type and formed at a second length when used on a second vehicle type.