Abstract: A hybrid component for lightweight, structural uses, including a steel member formed of a high strength steel; and a cast coupling member cast on a portion of the steel member by casting-in-place a semi-solid aluminum about the portion of the steel member, thereby positively and rigidly securing the coupling member to the steel member. A method of forming a hybrid component for lightweight, structural uses, including: forming a steel member formed of a high strength steel into a predetermined configuration; and casting a coupling member on a portion of the steel member by casting-in-place a semi-solid aluminum about the portion of the steel member, thereby positively and rigidly securing the coupling member to the steel member.

Abstract: A bumper system for mounting to a frame assembly of a motor vehicle at one end of the motor vehicle includes a bumper beam and an energy absorber. The bumper beam includes an upper beam wall, a lower beam wall, and a central beam wall between the upper and lower beam walls. The energy absorber is mounted to the bumper beam and includes an upper absorber wall, a lower absorber wall, and a central absorber wall between the upper and lower absorber walls. The energy absorber has a height that is greater than a height of the bumper beam such that the upper absorber wall is spaced upwardly above the upper beam wall and the lower absorber wall is spaced downwardly below the lower beam wall.