Abstract: The invention provides a method of joining dissimilar materials, such as aluminum to steel, by applying low pressure and heat to minimize distortion of the materials and the heat affected zone. The method includes applying current to a weld element, at least partially melting a portion of the first material with the heated weld element, and passing through the at least partially melted portion of the first material with the weld element. The method further includes contacting the second material with the heated weld element, and melting a portion of the weld element and a portion of the second material in contact with one another to form a weld. The weld element is designed with a head to trap the first material between the head and the second material, and a vent for receiving the at least partially melted first material as the weld element passes through.

Abstract: A sub-frame assembly for attachment to a unibody of a vehicle and for supporting at least one vehicular component is provided. The sub-frame assembly includes a pair of longitudinal members which are spaced from one another in a lateral direction and extend in a longitudinal direction between first and second ends. The longitudinal members at least partially converge towards one another from the first ends to the second ends such that the second ends are closer to one another than the first ends. A cross-member is coupled with and extends laterally between the longitudinal members. Each of the longitudinal members and the cross-member has a single and no more than one body mount for connection with the unibody of the vehicle such that the sub-frame assembly has exactly three body mounts in total.

Abstract: A sub-frame assembly for attachment to a unibody of a vehicle and for supporting at least one vehicular component is provided. The sub-frame assembly includes a pair of longitudinal members which are spaced from one another in a lateral direction and extend in a longitudinal direction between first and second ends. The longitudinal members at least partially converge towards one another from the first ends to the second ends such that the second ends are closer to one another than the first ends. A cross-member is coupled with and extends laterally between the longitudinal members. Each of the longitudinal members and the cross-member has a single and no more than one body mount for connection with the unibody of the vehicle such that the sub-frame assembly has exactly three body mounts in total.