Abstract: An expanded laminate and method of forming an expanded laminate are disclosed. In at least one embodiment, the method includes selectively applying a relatively high temperature-resistant material to a surface of a first metal sheet to form a covered portion and an uncovered portion and diffusion bonding the first metal sheet to a second metal sheet at the uncovered portion to form a bonded region and an unbonded region. Pressurized gas may be introduced between the first and second metal sheets to expand the first and second metal sheets in the unbonded region. The metal sheets may be aluminum sheets. The sheets may be positioned in a die having a plurality of cavities such that when the pressurized gas is introduced the sheets expand into the cavities. The diffusion bonding may be performed by applying pressure, for example, using rollers.

Abstract: An alloy composite material comprising an aluminum alloy layer and a thermal spray alloy layer of 20 to 40% Mn and 47 to 76% Fe by weight in overlaying contact with the aluminum alloy layer. An alloy composite material comprising an aluminum alloy layer or base layer and a thermal spray alloy layer of 20 to 40% Mn and 47 to 76% Fe by weight in overlaying contact with the aluminum alloy layer or base layer. The aluminum alloy layer or base layer and the thermal spray alloy layer have a mechanical compatibility to each other of 20-60 MPa as determined using tests specified by ASTM-C633 test. A process of thermal spraying comprising providing a base layer and a feed stock alloy of 20 to 40% Mn and 47 to 76% Fe and thermally spraying the feed stock alloy onto the base layer to form an alloy composite material.

Abstract: An impact absorbing assembly comprises a CFRP part including a first portion and a second portion that are connected by a metal bending hinge connector. The metal bending hinge connector bends in response to an impact force being applied to the assembly to inhibit the CFRP part from cracking. The metal bending hinge connector may be a tubular member that defines an opening extending from a first end to a second end of the tubular member. The tubular member receives the first CFRP part in the first end and the second CFRP part in the second end. The impact absorbing assembly may be, for example, a longitudinally extending rail or a sub-frame arm.

Abstract: A subframe for a vehicle includes a subframe structure and a rear end joint. The rear end joint is formed on the subframe structure for attachment to a floor via a bolt. The rear end joint defines a notch, having a collar surrounding the bolt. The rear end joint is configured such that, upon impact, the rear end joint interacts with the bolt to break the collar, split the notch, and detach the subframe structure from the floor.

Abstract: Systems and methods are provided for forming an engine comprising a thermoset composite engine block. One example method includes reinforcing the engine block with a plurality of metal strips, wherein a first portion of the plurality of metal strips are positioned in a substantially transverse direction of the engine block and a second portion of the plurality of metal strips are positioned in a substantially longitudinal direction of the engine block. The plurality of metal reinforcing strips may provide additional reinforcement to the engine block.

Abstract: A subframe for a vehicle includes a subframe structure and a rear end joint. The rear end joint is formed on the subframe structure for attachment to a floor via a bolt. The rear end joint defines a notch, having a collar surrounding the bolt. The rear end joint is configured such that, upon impact, the rear end joint interacts with the bolt to break the collar, split the notch, and detach the subframe structure from the floor.

Abstract: An impact absorbing assembly comprises a CFRP part including a first portion and a second portion that are connected by a metal bending hinge connector. The metal bending hinge connector bends in response to an impact force being applied to the assembly to inhibit the CFRP part from cracking The metal bending hinge connector may be a tubular member that defines an opening extending from a first end to a second end of the tubular member. The tubular member receives the first CFRP part in the first end and the second CFRP part in the second end. The impact absorbing assembly may be, for example, a longitudinally extending rail or a sub-frame arm.

Abstract: Methods of applying a corrosion protection layer and components protected thereby are disclosed. In one embodiment, a corrosion-resistant assembly is provided including a first metal component joined to a second metal component, a joint interface between the first and second components, and a corrosion protection layer covering at least a portion of the joint interface, the corrosion protection layer including aluminum or zinc. The corrosion protection layer (CPL) may be applied by a spraying process, such as thermal spraying. The CPL may be a non-structural coating and may be formed of commercially pure aluminum (e.g., at least 99 wt. %). The CPL may form a seal between two components at the joint interface, for example, when components are joined using a hem-lock. The CPL may also be applied to newly machined surfaces, such as cut surfaces and punch surfaces to prevent or reduce corrosion.

Abstract: A vehicle includes a frame, a bumper, and a crush can that secures the bumper to the frame. The crush can includes a plurality of cells that are arranged in a fanned configuration relative to the frame such that walls of the cells deform during offset impact events to deflect objects away from the frame.

Abstract: Systems and methods are provided for forming an engine comprising a thermoset composite engine block. One example method includes reinforcing the engine block with a plurality of metal strips, wherein a first portion of the plurality of metal strips are positioned in a substantially transverse direction of the engine block and a second portion of the plurality of metal strips are positioned in a substantially longitudinal direction of the engine block. The plurality of metal reinforcing strips may provide additional reinforcement to the engine block.

Abstract: In one or more embodiments, a composite die includes a die face defining a protrusion and including a first metal, and a die base supporting the die face, the die base including a housing, a first filler positioned within the housing and contacting the protrusion, and a bridging member reinforcing the housing, the housing including a second metal different than the first metal.

Abstract: An expanded laminate and method of forming an expanded laminate are disclosed. In at least one embodiment, the method includes selectively applying a relatively high temperature-resistant material to a surface of a first metal sheet to form a covered portion and an uncovered portion and diffusion bonding the first metal sheet to a second metal sheet at the uncovered portion to form a bonded region and an unbonded region. Pressurized gas may be introduced between the first and second metal sheets to expand the first and second metal sheets in the unbonded region. The metal sheets may be aluminum sheets. The sheets may be positioned in a die having a plurality of cavities such that when the pressurized gas is introduced the sheets expand into the cavities. The diffusion bonding may be performed by applying pressure, for example, using rollers.

Abstract: A structural polymer insert. The insert includes a substrate having a surface and an adhesive with the substrate being an admixture of a polypropylene component and a glass fiber component. The surface has a plurality of oxygen atoms, optionally introduced by air plasma, in an amount of 1 to 60 atomic percent of all the atoms present on the surface. The foam adhesive is attached to the surface through one or more reactive moieties resulted from oxidative action of the oxygen atoms.

Abstract: A beam sub-assembly for a vehicle includes a beam member and at least one carbon-fiber prepreg bonded to a first portion of an exterior surface of the beam member so as to cover an entire length of the beam member along the first portion.

Abstract: A structural polymer insert. The insert includes a substrate having a surface and an adhesive with the substrate being an admixture of a polypropylene component and a glass fiber component. The surface has a plurality of oxygen atoms, optionally introduced by air plasma, in an amount of 1 to 60 atomic percent of all the atoms present on the surface. The foam adhesive is attached to the surface through one or more reactive moieties resulted from oxidative action of the oxygen atoms.

Abstract: A friction stir spot welding tool and a self-piercing riveting tool are disclosed for joining parts. The parts are clamped between a head and anvil support of the friction stir spot welding tool or the self-piercing riveting tool. A plurality of clamping and heating modules are attached to an attachment fixture on the head and the anvil support that heats the area around the pin of the friction stir spot welding tool or self-piercing riveting tool prior to and during the joining operation.

Abstract: A deflector for a front end assembly that includes a lower tube having a lower/front leg extending outboard from a bumper and an intermediate leg extending from a lower/outer end of the lower/front leg to a sliding plate that is not attached to a frame rail. The deflector also includes an upper tube including an upper/front leg extending outboard from the bumper and a rear leg extending from an upper/outer end of the upper tube toward that is attached to a rear sliding plate that is also not attached to the frame rail. A method of making a deflector from an aluminum tube that is bent to shape and wrapped with a carbon fiber resin layer.

Abstract: In one or more embodiments, a composite die includes a die face defining a protrusion and including a first metal, and a die base supporting the die face, the die base including a housing, a first filler positioned within the housing and contacting the protrusion, and a bridging member reinforcing the housing, the housing including a second metal different than the first metal.

Abstract: According to one or more embodiments, a polymeric article includes a polymeric composition, which in turn includes a polymeric material in a first weight percent, a non-metallic fibrous material in a second weight percent, and a metallic fiber material in a third weight percent and being intermixed with the non-metallic fibrous material. The polymeric material may include at least one of epoxy, vinyl ester, and/or polyester. The fibrous material may include at least one of glass fiber and carbon fiber. The metallic fiber material may include at least one of steel and aluminum.

Abstract: An alloy composite material comprising an aluminum alloy layer and a thermal spray alloy layer of 20 to 40% Mn and 47 to 76% Fe by weight in overlaying contact with the aluminum alloy layer. An alloy composite material comprising an aluminum alloy layer or base layer and a thermal spray alloy layer of 20 to 40% Mn and 47 to 76% Fe by weight in overlaying contact with the aluminum alloy layer or base layer. The aluminum alloy layer or base layer and the thermal spray alloy layer have a mechanical compatibility to each other of 20-60 MPa as determined using tests specified by ASTM-C633 test. A process of thermal spraying comprising providing a base layer and a feed stock alloy of 20 to 40% Mn and 47 to 76% Fe and thermally spraying the feed stock alloy onto the base layer to form an alloy composite material.