Abstract: A method for forming a vehicle side rail structure includes forming a cylindrical tubular metal blank, forming a conical tubular metal blank, the conical tubular metal blank having a wider end portion and a narrower end portion, and joining the wider end portion of the conical tubular metal blank to one end portion of the cylindrical tubular metal blank by welding to form a welded tubular assembly. The method further includes bending the cylindrical tubular metal blank portion of the welded tubular assembly and hydroforming the welded tubular assembly by placing the welded tubular assembly into a hydroforming die cavity and pressuring an interior of the welded tubular assembly with hydroforming fluid so as to expand the welded tubular assembly into general conformity with surfaces defining the die cavity.

Abstract: A method of hydroforming a tubular structure of varying diameter along its longitudinal axis, comprising the formation of a tubular blank member by welding together, at their periphery, tubes of different diameters using electromagnetic pulse welding.

Abstract: An assembly of supporting members includes a first member overlapping a second member and positioned within a hollow interior of the second member. The hollow interior of the second member has a flange on which the first member rests. A leading edge of the first member may have a protrusion extending away from the first member towards the flange of the second member to protect the flange and the connection between the first and second members. The first and second members may be hydroformed with the protrusion being an integral element of the first member.

Abstract: An apparatus and method for welding members that are formed at least in part of aluminum. A welding assembly is constructed and arranged to position a welding material in electrically conductive relation between exterior surface portions of first and second weldable members at a location where the first and second weldable members are to be joined. The welding material assembly includes at least one welding material member mounted on a flexible carrier sheet in a predetermined arrangement with each welding material member being constructed of an electrically conductive metallic welding material capable of melting when heated by application of an electrical current. A welding method includes alternatively attaching the welding material members to a weldable member without a carrier sheet, by a welding process.

Abstract: A welding material assembly is constructed and arranged to position a welding material in electrically conductive relation between exterior surface portions of first and second weldable members at a location where the first and second weldable members are to be joined. The welding material assembly includes at least one welding material member mounted on a flexible carrier sheet in a predetermined arrangement with each welding material member being constructed of an electrically conductive metallic welding material capable of melting when heated by application of an electrical current. Each welding material member is mounted on the sheet such that when the sheet is placed between the exterior surfaces of the first and second weldable members to be welded, each welding material member is electrically conductively disposed therebetween.

Abstract: A welding material is constructed and arranged to be positioned in electrically conductive relation between exterior surface portions of first and second weldable members at a location where the first and second weldable members are to be joined. The welding material includes at least one welding material member constructed of an electrically conductive metallic welding material capable of melting when heated by application of an electrical current. Each welding material member is mounted on the exterior surface of the first weldable member and then positioned between the exterior surfaces of the first and second weldable members to be electrically conductively disposed therebetween.

Abstract: A method of forming this vehicle space frame joint is carried out by (1) forming an elongated first member constructed of a metallic material that includes an end segment having a predetermined length and having an exterior surface that defines an exterior configuration of the end segment; (2) forming an elongated tubular hydroformed second member by hydroforming a tubular blank having a tubular metallic wall so as to outwardly deform the tubular metallic wall into a predetermined exterior surface configuration determined by the engagement of the tubular metallic wall with die surfaces of a die assembly, the hydroformed second member having an intermediate segment that includes first and second spaced apart wall portions; (3) forming generally aligned first and second openings within the first and second wall portions, respectively, of the intermediate segment of the second member, the first and second openings being of complimentary configuration to portions of the exterior surface of the end segment of the

Abstract: A welding material assembly is constructed and arranged to position a welding material in electrically conductive relation between exterior surface portions of first and second weldable members at a location where the first and second weldable members are to be joined. The welding material assembly includes at least one welding material member mounted on a flexible carrier sheet in a predetermined arrangement, each welding material member being constructed of an electrically conductive metallic welding material capable of melting when heated by application of an electrical current and each carrier sheet being constructed of a material that is electrically nonconductive. Each welding material member is mounted on the sheet such that when the sheet is placed between the exterior surfaces of said first and second weldable members to be welded each said welding material member is electrically conductively disposed therebetween.

Abstract: A method of hydroforming a tubular structure of varying diameter along its longitudinal axis, comprising the formation of a tubular blank member by welding together, at their periphery, tubes of different diameters using electromagnetic pulse welding.

Abstract: A method of forming this vehicle space frame joint is carried out by (1) forming an elongated first member constructed of a metallic material that includes an end segment having a predetermined length and having an exterior surface that defines an exterior configuration of the end segment; (2) forming an elongated tubular hydroformed second member by hydroforming a tubular blank having a tubular metallic wall so as to outwardly deform the tubular metallic wall into a predetermined exterior surface configuration determined by the engagement of the tubular metallic wall with die surfaces of a die assembly, the hydroformed second member having an intermediate segment that includes first and second spaced apart wall portions; (3) forming generally aligned first and second openings within the first and second wall portions, respectively, of the intermediate segment of the second member, the first and second openings being of complimentary configuration to portions of the exterior surface of the end segment of the

Abstract: A space frame for a motor vehicle is provided to illustrate an embodiment of the invention. The space frame includes a pair of upper longitudinal members. Each of the upper longitudinal members has a pillar forming portion and a first portion coupled to the pillar forming portion. The space frame also includes a cross member having a second portion and a pair of leg portions extending from junctures at each end of the second portion. The space frame additionally includes a pair of laterally spaced side rail structures, which are assembled such that the pillar forming portion of each upper longitudinal member is connected to and forms a pillar on a respective side rail structure. The leg portions of the cross member are each connected to a respective side rail structure and extend upwardly therefrom. The second portion of the cross member connects the pair of side rail structures in laterally spaced relation.

Abstract: A welding material in positioned in electrically conductive relation between exterior surface portions of first and second weldable members, such as hydroformed tubes, at a location where the first and second weldable members are to be joined. A welding device comprises first and second electrodes or conductive ends that extend along substantially the entire extent of first sides of the first and second weldable members, respectively. The first and second conductive ends include first and second concave recesses, which nest with the first and second weldable members, respectively. Electrical current is applied across the first and second weldable members by the nesting first and second conductive ends such that the applied current melts the welding material and thereby welds the exterior surface portions to one another. The welding device can be mounted on a robotic mechanism, which can move the welding device between first and second welding positions.

Abstract: A space frame includes a pair of laterally spaced, longitudinally extending side rail structures and longitudinally spaced pairs of laterally spaced upright structures having joints at their lower ends with the pair of side rail structures. The longitudinal spaced pairs of laterally spaced upright structures extend upwardly from the side rails structures and define a plurality of pairs of pillars, including a pair of forward A pillars, a longitudinally spaced pair of B pillars, and a longitudinally spaced pair of rearward end pillars. A pair of the side roof structures has joints with the pair of A pillars. The pair of side roof structures extends longitudinally rearwardly from the pair of A pillars and have joints with the pair of B pillars and with the pair of rearward end pillars. Longitudinally spaced cross structures have joints with the pair of side rail structures, with the pair of A pillars and with the pair of side roof structures.

Abstract: A door seal interface structure for a motor vehicle space frame includes a longitudinally extending hydroformed tubular rail portion, a hydroformed tubular pillar portion connected at a joint to the rail portion and a transition structure. The rail portion and the pillar portion provide respective surface portions constructed and arranged to sealingly engage a door seal to seal a peripheral portion of a closed vehicle door. The pillar and rail surface portions are angularly related to one another in the vicinity of the joint. The transition structure is mounted on the rail portion and the pillar portion in the vicinity of the joint and provides a transition surface that provides a transition between the pillar and rail surfaces of the pillar and rail portions, the transition surface portion being constructed and arranged to sealingly engage a portion of the door seal to seal the closed vehicle door and thereby provide a door seal-engagable surface in the vicinity of the joint.

Abstract: A method of forming this vehicle space frame joint is carried out by (1) forming an elongated first member constructed of a metallic material that includes an end segment having a predetermined length and having an exterior surface that defines an exterior configuration of the end segment; (2) forming an elongated tubular hydroformed second member by hydroforming a tubular blank having a tubular metallic wall so as to outwardly deform the tubular metallic wall into a predetermined exterior surface configuration determined by the engagement of the tubular metallic wall with die surfaces of a die assembly, the hydroformed second member having an intermediate segment that includes first and second spaced apart wall portions; (3) forming generally aligned first and second openings within the first and second wall portions, respectively, of the intermediate segment of the second member, the first and second openings being of complimentary configuration to portions of the exterior surface of the end segment of the

Abstract: A space frame includes a pair of laterally spaced, longitudinally extending side rail structures and longitudinally spaced pairs of laterally spaced upright structures having joints at their lower ends with the pair of side rail structures. The longitudinal spaced pairs of laterally spaced upright structures extend upwardly from the side rails structures and define a plurality of pairs of pillars, including a pair of forward A pillars, a longitudinally spaced pair of B pillars, and a longitudinally spaced pair of rearward end pillars. A pair of the side roof structures has joints with the pair of A pillars. The pair of side roof structures extends longitudinally rearwardly from the pair of A pillars and have joints with the pair of B pillars and with the pair of rearward end pillars. Longitudinally spaced cross structures have joints with the pair of side rail structures, with the pair of A pillars and with the pair of side roof structures.