Abstract: A welding backing insert (20) includes a body (22), a retention member (24) and an insertion member (26). The retention member (24) includes at least one leg (28) being deflectable to enable insertion into a hollow profile structural extrusions (14). At least one leg (28) tries to return to its original position exerting a force on the hollow profile structural extrusion (14) to retain the backing insert (20) in the hollow profile structural extrusion (14). The insertion member (26) projects from the body for inserting into a second hollow profile structural extrusion (14). A gap-control joint spacer (50) projects from the body to provide a gap between adjacent hollow profile structural extrusions.

Abstract: The present disclosure provides a method that includes providing a first blank including an upper major surface, a lower major surface, and a plurality of side surfaces that connect the lower major surface to the upper major surface. The upper and lower major surfaces each includes a coating that includes aluminum, and the side surfaces are devoid of the coating. The method also includes forming an additive layer on at least one of the side surfaces that is devoid of the coating, and includes laser welding the first blank including the additive layer to a second blank, wherein a thickness of the additive layer is such that during the laser welding, the laser irradiates a material of the additive layer without irradiating the coating to form a weld pool that includes the material of the additive layer and does not include the aluminum of the coating.

Abstract: A welding backing insert (20) includes a body (22), a retention member (24) and an insertion member (26). The retention member (24) includes at least one leg (28) being deflectable to enable insertion into a hollow profile structural extrusions (14). At least one leg (28) tries to return to its original position exerting a force on the hollow profile structural extrusion (14) to retain the backing insert (20) in the hollow profile structural extrusion (14). The insertion member (26) projects from the body for inserting into a second hollow profile structural extrusion (14). A gap-control joint spacer (50) projects from the body to provide a gap between adjacent hollow profile structural extrusions.

Abstract: The present disclosure provides a method that includes providing a first blank including an upper major surface, a lower major surface, and a plurality of side surfaces that connect the lower major surface to the upper major surface. The upper and lower major surfaces each includes a coating that includes aluminum, and the side surfaces are devoid of the coating. The method also includes forming an additive layer on at least one of the side surfaces that is devoid of the coating, and includes laser welding the first blank including the additive layer to a second blank, wherein a thickness of the additive layer is such that during the laser welding, the laser irradiates a material of the additive layer without irradiating the coating to form a weld pool that includes the material of the additive layer and does not include the aluminum of the coating.

Abstract: A protective system for a high voltage module of an electrified vehicle arranged at least partially in a crush zone of the vehicle comprises a housing defining a front end and a rear end and having the high voltage module disposed therein, wherein the front end is securely connected to a frame of the vehicle and the rear end is disconnected from or loosely connected to the frame, the front end including high voltage wiring for the high voltage module, and a displacement device connected to the frame behind the rear end of the housing, wherein in response to a vehicle impact event that compresses the frame in the crush zone, the displacement is configured to vertically displace the rear end of the housing and the high voltage module therein, thereby protecting the high voltage module and the high voltage wiring from damage during compression of the crush zone.

Abstract: A one-piece blow molded bumper end cap is provided for use in combination with a vehicle bumper assembly. The bumper end cap functions as an end plug to enhance air flow into the engine compartment when used in combination with a flow-through bumper. The bumper end cap also includes structural features which improve the crashworthiness of the bumper system in lower speed corner impacts, as well as, higher speed frontal impacts.

Abstract: A cross beam is mounted in a vehicle body between cowls on opposite sides of the vehicle body in a position to support a steering column. A bracket on one end of the beam has two slots which engage two locator studs on one of the cowls and provide increased body torsional stiffness. A second bracket is sleeved on the opposite end of the beam and has one slot engageable with a locator stud on the other cowl. The beam can be hung in the vehicle on these locator studs prior to driving fasteners which rigidly secure the brackets to the cowls. The second bracket may then be rigidly bolted to the beam.