Abstract: A method of producing a laminated article comprising placing a first metal skin, a core, and a second metal skin freely onto each other as discreet layers to provide a layered component; and forming the layered component into a shaped article via a die prior to producing a laminated article by applying pressure and heat to the shaped article, wherein at least the first skin moves relative to the core and/or second skin during the forming.

Abstract: This disclosure details overmolded vehicle sheet metal structures that included integrated attachments for achieving part integration. An exemplary sheet metal structure includes a sheet metal panel, a reinforcing structure molded on the sheet metal panel, and an integrally molded attachment structure formed within the reinforcing structure. In some embodiments, the integrally molded attachment structure may include a nut, a bracket, or both. An additional vehicle component may be attached to the sheet metal panel via the integrally molded attachment structure. The sheet metal structure may be formed in a single shot injection molding process.

Abstract: This disclosure details overmolded vehicle sheet metal structures that included integrated attachments for achieving part integration. An exemplary sheet metal structure includes a sheet metal panel, a reinforcing structure molded on the sheet metal panel, and an integrally molded attachment structure formed within the reinforcing structure. In some embodiments, the integrally molded attachment structure may include a nut, a bracket, or both. An additional vehicle component may be attached to the sheet metal panel via the integrally molded attachment structure. The sheet metal structure may be formed in a single shot injection molding process.

Abstract: A method of producing a laminated article comprising placing a first metal skin, a core, and a second metal skin freely onto each other as discreet layers to provide a layered component; and forming the layered component into a shaped article via a die prior to producing a laminated article by applying pressure and heat to the shaped article, wherein at least the first skin moves relative to the core and/or second skin during the forming.

Abstract: A method of producing a laminated article comprising placing a first metal skin, a core, and a second metal skin freely onto each other as discrete layers to provide a layered component; and forming the layered component into a shaped article via a die prior to producing a laminated article by applying pressure and heat to the shaped article, wherein at least the first skin moves relative to the core and/or second skin during the forming.

Abstract: A micro-alloyed manganese-boron steel includes about 0.25 to 0.4 wt. % carbon, about 0.5 to 2.7 wt. % manganese, about 0.001 to 0.005 wt. % boron, about 0.1 to 0.8 wt. % silicon, about 0.1 to 0.6 wt. % chromium, molybdenum and nickel, and about 0.01 to 0.06 wt. % aluminum, niobium and titanium. The balance is iron, and the steel is a micro-alloyed material for hot stamping of automotive parts.

Abstract: A method of producing a laminated article comprising placing a first metal skin, a core, and a second metal skin freely onto each other as discreet layers to provide a layered component; and forming the layered component into a shaped article via a die prior to producing a laminated article by applying pressure and heat to the shaped article, wherein at least the first skin moves relative to the core and/or second skin during the forming.

Abstract: A vehicle body assembly includes an outer component defining a cavity. The outer component has a pair of first flanges. An inner component has a pair of second flanges each joined to one of the first flanges. A reinforcement formed of carbon fiber is disposed in the cavity between the components. The reinforcement includes a faceplate joined to the outer component with a rivet and third flanges each joined to the inner component with a rivet.

Abstract: A shock tower assembly includes a cast shock tower body composed of magnesium or magnesium alloy and at least one steel bridging bracket. An insulating adhesive layer is formed between the tower body and the bracket. A mechanical fastener is used for fastening the tower body to the bracket. One or more structural ribbings are formed on the tower body. The mechanical fastener may be selected from any of several mechanical fasteners, including self-piercing rivets. Alternatively, a screw boss may be formed for receiving a screw. The rivet may be inserted from the bracket into the shock tower body or from the shock tower body into the bracket in which case an insulating layer is positioned between the head of the self-piercing rivet and the cast shock tower body. A sealant is preferably formed along the intersection of the cast shock tower body and the steel bridging bracket.

Abstract: A shock tower assembly includes a cast shock tower body composed of magnesium or magnesium alloy and at least one steel bridging bracket. An insulating adhesive layer is formed between the tower body and the bracket. A mechanical fastener is used for fastening the tower body to the bracket. One or more structural ribbing are formed on the tower body. The mechanical fastener may be selected from any of several mechanical fasteners, including self-piercing rivets. Alternatively, a screw boss may be formed for receiving a screw. The rivet may be inserted from the bracket into the shock tower body or from the shock tower body into the bracket in which case an insulating layer is positioned between the head of the self-piercing rivet and the cast shock tower body. A sealant is preferably formed along the intersection of the cast shock tower body and the steel bridging bracket.

Abstract: A system is provided for attaching a layer of a metal to other layers in a material stack-up using a metal mechanical fastener that does not allow for direct contact between the fastener and the metal layer, thereby neutralizing any galvanic reaction between the metal sheet and the fastener and avoiding corrosion. The metal layer may be any of several metals, including magnesium. The fastener is a rivet, a screw or a bolt. The disclosed inventive concept uses an insulating layer to insulate the magnesium layer. In one embodiment, a layer of a thin metal is formed over the insulating layer. Where the fastener is a rivet and the metal is magnesium, the insulating layer and thin metal provide a barrier between the magnesium layer and the rivet prongs following rivet insertion, thus isolating the rivet. The system enables a greater application of fastener joining, particularly with magnesium and mixed material joining.

Abstract: A vehicle frame includes an outside rail section having an upper flange, a lower flange, and an inward facing cavity between the upper and lower flanges. An inside rail section is coupled along the upper and lower flanges of the outside rail section and has an outward facing cavity that aligns with the inward facing cavity to enclose an interior volume. A pair of hydroform tubes extending vertically through apertures at spaced longitudinal locations in the upper flange and engage a bottom surface of the inward cavity to define a pillar for supporting a vehicle roof.

Abstract: A vehicle roof panel for channeling fluid includes a raised formation at a centerline of the vehicle, and a plurality of primary troughs disposed laterally on either side of the raised formation. Each of the primary troughs defines a base surface that is recessed below a global runoff curvature of the roof. The roof panel also includes a secondary trough positioned laterally outboard of the primary troughs that defines a base surface that is substantially aligned with the global runoff curvature.

Abstract: A vehicle frame includes an outside rail section having an upper flange, a lower flange, and an inward facing cavity between the upper and lower flanges. An inside rail section is coupled along the upper and lower flanges of the outside rail section and has an outward facing cavity that aligns with the inward facing cavity to enclose an interior volume. A pair of hydroform tubes extending vertically through apertures at spaced longitudinal locations in the upper flange and engage a bottom surface of the inward cavity to define a pillar for supporting a vehicle roof.

Abstract: A vehicle pillar assembly is provided which includes a roof rail, a rocker, a first hollow support member, and a second hollow support member. The first hollow support member and the second hollow support member each includes a first wall, a second wall, a third wall and optionally a fourth wall. The first hollow support member and the second hollow support member each include a tubular lower area that extends upwardly from the rocker panel. The tubular lower area includes at least one crush initiator. The first hollow support member and the second hollow support member also each include an upper section that extends downwardly from the roof rail.

Abstract: A vehicle roof support assembly is provided which includes a roof rail, a rocker panel, a first hollow support member and a second hollow support member. The first hollow support member and the second hollow support member each includes an inner wall, an outer wall, a front wall, a front wall and a rear wall. The first hollow support member and the second hollow support member each include a tubular lower area that extends upwardly from the rocker panel. The first hollow support member and the second hollow support member also each include an upper section that extends downwardly from the roof rail. The first hollow support member and the second hollow support member are spaced apart from one another in at least a middle area of the first and second hollow support members.

Abstract: A multi-functional radiator support assembly is provided for a motor vehicle. The multi-functional radiator support assembly includes a radiator support for operative attachment to forward end of the motor vehicle. The radiator support is made of magnesium or a magnesium alloy material.

Abstract: A method is provided for coating a radiator support assembly for a motor vehicle including the steps of providing magnesium components for the radiator support assembly and coating the magnesium components. The method also includes the steps of assembling the magnesium components into the radiator support assembly and painting the radiator support assembly.

Abstract: A multi-functional radiator support assembly is provided for a motor vehicle. The multi-functional radiator support assembly includes a radiator support being made of a first metal material for operative attachment to forward end of the motor vehicle. The first metal material is a die cast metal material. The multi-functional radiator assembly also includes at least one spacer being made of a second metal material different from the first metal material for being disposed between the radiator support and either one of a body and frame of the motor vehicle to resist galvanic corrosion of the radiator support.

Abstract: A lamp can and radiator support assembly is provided for a motor vehicle. The lamp can and radiator support assembly includes a radiator support for operative attachment to forward end of the motor vehicle. The lamp can and radiator support assembly also includes a pair of lamp cans attached to the radiator support. The lamp can and radiator support assembly further includes at least one crossbar interconnecting the lamp cans and attached to the radiator support for adjusting the lamp cans relative to a body of the motor vehicle.