Abstract: A battery enclosure assembly includes first and second pieces of an enclosure having an interior area, a plurality of fasteners joining the first and second pieces at a fastening interface, and a seal system sealing the first and second pieces at a sealing interface that is outside the plurality of fasteners relative to the interior area. The seal system including a cured gasket and a non-setting sealant.

Abstract: A structural enclosure includes a pair of aluminum rails with an upper wall and a lower wall spaced apart from the upper wall, a plurality of sleeves extending into and captured within the aluminum rails, and each of the plurality of sleeves having a head with a predefined thickness disposed on an outer surface of the aluminum rails and configured to separate the outer surface of the aluminum rails from a steel vehicle chassis to which the aluminum rails are mounted. The structural enclosure can be an aluminum battery box for an electric vehicle and the aluminum battery box can be mounted to and electrochemically isolated from the steel vehicle chassis.

Abstract: A structural enclosure includes a pair of aluminum rails with an upper wall and a lower wall spaced apart from the upper wall, a plurality of sleeves extending into and captured within the aluminum rails, and each of the plurality of sleeves having a head with a predefined thickness disposed on an outer surface of the aluminum rails and configured to separate the outer surface of the aluminum rails from a steel vehicle chassis to which the aluminum rails are mounted. The structural enclosure can be an aluminum battery box for an electric vehicle and the aluminum battery box can be mounted to and electrochemically isolated from the steel vehicle chassis.

Abstract: This disclosure relates to a battery assembly with an aluminum (Al) alloy, ceramic coated header plate. An example battery assembly includes a plate, which may be referred to as a header plate, configured to support an electrical connector. The plate includes aluminum (Al) alloy and is coated with a layer of ceramic material.

Abstract: This disclosure relates to a battery assembly with an aluminum (Al) alloy, ceramic coated header plate. An example battery assembly includes a plate, which may be referred to as a header plate, configured to support an electrical connector. The plate includes aluminum (Al) alloy and is coated with a layer of ceramic material.

Abstract: An assembly and a method of joining a first part with a second part at an attachment area that includes a localized area on the first part. The localized area is cleaned and activated by a plasma jet. An organosilicon composition is applied by plasma-enhanced chemical vapor deposition to the localized area. An adhesive is applied to the localized area and the second part is mechanically fastened to the first part in the localized area.

Abstract: A vehicle includes a steel frame, steel bracket, an e-coating layer, and an aluminum cargo bed. The steel frame has a top side. The steel bracket has a zinc-plating, is secured to the top side of the steel frame, and has an upper surface that faces away from the frame. The e-coating layer is deposited externally and collectively on the steel frame and steel bracket. The aluminum cargo bed is secured to the upper surface such that the zinc-plating and e-coating layer are sandwiched between the steel bracket and aluminum cargo bed.

Abstract: A friction-welded ground assembly that includes an alloy substrate with a clearance hole; an aluminum alloy weld nut having a bolt bore and an outer wall; and a grounding bolt. The bore is located substantially within the clearance hole and a portion of the outer wall is joined to the substrate at a friction-welded attachment. Further, the bolt is threaded within the bore. In addition, a method for making a ground includes the steps: rotating an aluminum alloy weld nut having an outer wall at a predetermined speed; lowering the outer wall of the rotating nut into contact with an aluminum alloy substrate to generate a frictional force for a friction time; arresting the rotation of the nut; and applying an axial forging force to the outer wall and the substrate for a forging time.

Abstract: A joint for a motor vehicle body comprises a first structural member fabricated from aluminum attached to a second structural member fabricated from steel. The second structural member has an adjoining portion that is in substantially juxtaposed abutting relation with the first structural member when the second structural member is attached to the first structural member. The second structural member has a ramp portion terminating in a bare exposed edge on the second structural member and upon which the bare exposed edge is disposed. The bare exposed edge is displaced from the first structural member to form a gap between the first structural member and the bare exposed edge to prevent corrosion of the bare exposed edge without the use of adhesives and sealants.

Abstract: A friction-welded ground assembly that includes an alloy substrate with a clearance hole; an aluminum alloy weld nut having a bolt bore and an outer wall; and a grounding bolt. The bore is located substantially within the clearance hole and a portion of the outer wall is joined to the substrate at a friction-welded attachment. Further, the bolt is threaded within the bore. In addition, a method for making a ground includes the steps: rotating an aluminum alloy weld nut having an outer wall at a predetermined speed; lowering the outer wall of the rotating nut into contact with an aluminum alloy substrate to generate a frictional force for a friction time; arresting the rotation of the nut; and applying an axial forging force to the outer wall and the substrate for a forging time.

Abstract: A method for providing a corrosion-resistant barrier between bolted dissimilar metals comprising the steps of disposing epoxy adhesive tape on at least one of a first and second metal member, curing the epoxy adhesive tape, applying a corrosion-resistant layer to the first and second metal members, and bolting the first and second metal members together such that the cured epoxy adhesive tape is positioned between the first and second metal members.

Abstract: A friction-welded ground assembly that includes an alloy substrate with a clearance hole; an aluminum alloy weld nut having a bolt bore and an outer wall; and a grounding bolt. The bore is located substantially within the clearance hole and a portion of the outer wall is joined to the substrate at a friction-welded attachment. Further, the bolt is threaded within the bore. In addition, a method for making a ground includes the steps: rotating an aluminum alloy weld nut having an outer wall at a predetermined speed; lowering the outer wall of the rotating nut into contact with an aluminum alloy substrate to generate a frictional force for a friction time; arresting the rotation of the nut; and applying an axial forging force to the outer wall and the substrate for a forging time.

Abstract: An assembly and a method of joining a first part with a second part at an attachment area that includes a localized area on the first part. The localized area is cleaned and activated by a plasma jet. An organosilicon composition is applied by plasma-enhanced chemical vapor deposition to the localized area. An adhesive is applied to the localized area and the second part is mechanically fastened to the first part in the localized area.

Abstract: A joint for a motor vehicle body comprises a first structural member fabricated from aluminum attached to a second structural member fabricated from steel. The second structural member has an adjoining portion that is in substantially juxtaposed abutting relation with the first structural member when the second structural member is attached to the first structural member. The second structural member has a ramp portion terminating in a bare exposed edge on the second structural member and upon which the bare exposed edge is disposed. The bare exposed edge is displaced from the first structural member to form a gap between the first structural member and the bare exposed edge to prevent corrosion of the bare exposed edge without the use of adhesives and sealants.

Abstract: An assembly and a method of joining a first part with a second part at an attachment area that includes a localized area on the first part. The localized area is cleaned and activated by a plasma jet. An organosilicon composition is applied by plasma-enhanced chemical vapor deposition to the localized area. An adhesive is applied to the localized area and the second part is mechanically fastened to the first part in the localized area.

Abstract: A joint for a motor vehicle body comprises a first structural member fabricated from aluminum attached to a second structural member fabricated from steel. The second structural member has an adjoining portion that is in substantially juxtaposed abutting relation with the first structural member when the second structural member is attached to the first structural member. The second structural member has a ramp portion terminating in a bare exposed edge on the second structural member and upon which the bare exposed edge is disposed. The bare exposed edge is displaced from the first structural member to form a gap between the first structural member and the bare exposed edge to prevent corrosion of the bare exposed edge without the use of adhesives and sealants.

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 front end structure includes a longitudinally extending upper tube, and a longitudinally extending lower tube. The upper and lower tubes are conjoined to each other along a substantial portion of the total length of the tubes. The front end structure also includes a coupling bracket that is secured to an outer wall of each of the upper and lower tubes near a rear edge of the tubes. The coupling bracket also includes an extension tab cantilevered from the rear edge of the tubes. Additionally, the front end structure includes a hinge pillar defining a first vertical mounting surface secured to an inner wall of the upper and lower tubes. The hinge pillar also defines a second vertical mounting surface secured to the extension tab of the coupling bracket.

Abstract: A vehicle front end structure includes a longitudinally extending upper tube, and a longitudinally extending lower tube. The upper and lower tubes are conjoined to each other along a substantial portion of the total length of the tubes. The front end structure also includes a coupling bracket that is secured to an outer wall of each of the upper and lower tubes near a rear edge of the tubes. The coupling bracket also includes an extension tab cantilevered from the rear edge of the tubes. Additionally, the front end structure includes a hinge pillar defining a first vertical mounting surface secured to an inner wall of the upper and lower tubes. The hinge pillar also defines a second vertical mounting surface secured to the extension tab of the coupling bracket.

Abstract: An assembly and a method of joining a first part with a second part at an attachment area that includes a localized area on the first part. The localized area is cleaned and activated by a plasma jet. An organosilicon composition is applied by plasma-enhanced chemical vapor deposition to the localized area. An adhesive is applied to the localized area and the second part is mechanically fastened to the first part in the localized area.