Abstract: Link arms for use in suspension systems are produced through an extrusion and friction stir welding process. Blocks having an eye and a planar body section are formed through an extrusion process. These sections are then paired together and joined through friction stir welding. The welded joint(s) is/are positioned in such a location so as to not impact the structural integrity of the completed component. Through this process it is possible to construct cost competitive link arms having the same or better structural integrity as previously employed steel link arms while achieving dramatic weight reductions.

Abstract: A method of welding together a motor vehicle structural assembly is available. The vehicle structural assembly includes a boxed member including an outboard wall, a top wall, a bottom wall and an inboard wall spaced from the outboard wall. The inboard wall has an opening therein. The motor vehicle structural assembly also includes a cylindrical support including a first end and a shoulder spaced from the first end at least the distance the boxed member inboard wall is spaced from the boxed member outboard wall. The method comprises spinning the support and advancing the support through the inboard wall opening so that the support first end is friction welded to the outboard wall and so that the support shoulder is friction welded to the inboard wall.

Abstract: The invention provides an automated system for welding a first metal part to a second metal part. The system includes a trainable articulated arm, and a moving mechanism for moving the arm. The moving mechanism comprises servos connected to the arm for moving the arm, and a robot controller connected to the mechanized means for controlling the movement of the articulated arm. The system further includes a welding torch, and a probe with physical dimensions comparable to the torch. The probe includes a seam tracking mechanism for tracking the location of a weld seam in response to movement of the probe along the seam, and a connector for transmitting probe movement to the controller. The system further includes a holder mounted on the articulated arm for interchangeable receiving the torch and the probe so that the torch and the probe assume essentially the same position relative to the arm. The invention also provides a method of welding a first metal part to a second metal part using the above system.

Abstract: A method for assembling a motor vehicle frame including a rail having a generally planar outer surface and upper and lower ends, and a bracket including a wall portion having a lower end, the method comprising the steps of positioning the bracket against the side rail outer surface so that the wall portion extends transversely to the rail outer surface, and welding the bracket to the rail by providing a weld bead along the junction between the wall portion and the rail outer surface and extending the weld bead along the rail outer surface substantially beyond the lower end of the wall portion to the lower end of the rail.