Abstract: A panel assembly is formed by a plurality of bonds between two sheet materials in a face to face relationship to form a preform. The plurality of bonds define a closed perimeter region between the two sheet materials and an open perimeter region between the two sheet materials. The preform may be formed into a predefined shape. Pressurized fluid is applied through an inlet into the open perimeter region to expand the preform. The pressurized fluid expands the open perimeter region such that the two sheet materials expand in an opposing direction, thereby defining an expanded open perimeter region. The closed perimeter region between the two sheet materials remains vacant of the pressurized fluid such that the closed perimeter region is not expanded. The expanded open perimeter region is filled with a filler material for improving a performance characteristic of the panel assembly, e.g., strength, sound absorption, or stiffness.

Abstract: A repair system includes a scanning system configured for determining a contour of a void surface. The repair system also includes an additive manufacturing system configured for sequentially printing a plurality of individual layers each disposed on one another adjacent the void surface according to the contour. A method of repairing a substrate having a damaged portion defining a void and having the void surface is also disclosed.

Abstract: Disclosed herein is an article comprising a first metal layer; a second metal layer that is chemically different from the first metal layer; and a third metal layer disposed between the first metal layer and the second metal layer and contacting both the first metal layer and the second metal layer; where the third metal layer is chemically similar to either the first metal layer or the second metal layer; where at least two metal layers that are chemically similar are welded together through a clearance opening located in a metal layer that is not chemically similar to the at least two metal layers.

Abstract: A method of injecting a liquid between a first panel and a second panel positioned flat against each other includes providing a tool defining an internal passageway having an inlet and an outlet. The first panel and the second panel are separated with the tool, to form a pocket between the first panel and the second panel, such that the outlet of the passageway is positioned in fluid communication with the pocket. A liquid source is connected to the inlet of the passageway to supply a liquid to the passageway. The liquid is injected into the pocket formed between the first panel and the second panel through the outlet of the passageway of the tool. The pocket is compressed or flattened to wet-out the liquid. The pocket may be compressed with the separating and injecting tool, or with a different device, such as a compressor or clamp.

Abstract: The indexing self-aligning hardware tool can join components and includes a first tool section including a die carrier, one or more dies coupled to the die carrier, and a first locator coupled to the die carrier. The indexing self-aligning hardware tool also includes a second tool section having a support body, one or more blankholders coupled to the support body, one or more punches movably disposed inside the blankholders, and a second locator coupled to the support body. The first locator and the second locator are configured to mate with a product feature locator of a component to align the first tool section relative to the second tool section.

Abstract: An integrated amalgamation carrier can join parts. The integrated amalgamation carrier includes an amalgamation carrier body elongated along a longitudinal axis. In addition, the integrated amalgamation carrier includes a plurality of fasteners protruding from the amalgamation carrier body. The fasteners are integrated with the amalgamation body to form a one-piece structure.

Abstract: A panel assembly is formed by a plurality of bonds between two sheet materials in a face to face relationship to form a preform. The plurality of bonds define a closed perimeter region between the two sheet materials and an open perimeter region between the two sheet materials. The preform may be formed into a predefined shape. Pressurized fluid is applied through an inlet into the open perimeter region to expand the preform. The pressurized fluid expands the open perimeter region such that the two sheet materials expand in an opposing direction, thereby defining an expanded open perimeter region. The closed perimeter region between the two sheet materials remains vacant of the pressurized fluid such that the closed perimeter region is not expanded. The expanded open perimeter region is filled with a filler material for improving a performance characteristic of the panel assembly, e.g., strength, sound absorption, or stiffness.

Abstract: A fastenerless anti-peel adhesive joint includes a first part having a first surface and forming a first anti-peel feature including a first anti-peel surface, a second part having a second surface and forming a second anti-peel feature including a second anti-peel surface, and an adhesive disposed between the first and second surfaces and within the first and second anti-peel features. The adhesive connects the parts via adhesive bonds at the first and second surfaces and at the first and second anti-peel surfaces. The first and second anti-peel features are configured to load the adhesive bonds at the first and second anti-peel surfaces in shear stress when the fastenerless anti-peel adhesive joint is subjected to a peel force that is normal to the first and second surfaces such that the shear strength of the adhesive bonds at the first and second anti-peel surfaces prevents the parts from being peeled apart.

Abstract: A panel assembly is formed by a plurality of bonds between two sheet materials in a face to face relationship to form a preform. The plurality of bonds define a closed perimeter region between the two sheet materials and an open perimeter region between the two sheet materials. The preform may be formed into a predefined shape. Pressurized fluid is applied through an inlet into the open perimeter region to expand the preform. The pressurized fluid expands the open perimeter region such that the two sheet materials expand in an opposing direction, thereby defining an expanded open perimeter region. The closed perimeter region between the two sheet materials remains vacant of the pressurized fluid such that the closed perimeter region is not expanded. The expanded open perimeter region is filled with a filler material for improving a performance characteristic of the panel assembly, e.g., strength, sound absorption, or stiffness.

Abstract: A visual inspection method includes the following steps: (a) placing a material between a pair of parts, wherein at least one of the pair of parts defines at least one thru-hole sized to partly receive the material; (b) pressing the pair of parts together until the material is partly displaced into the thru-hole (or merely moving the pair of parts toward each other until the material is partly displaced into the thru-hole); and (c) visually inspecting the one thru-hole to verify that the material is partly disposed in the thru-hole after pressing the pair of parts together (or moving the pair of parts toward each other).

Abstract: A fastenerless anti-peel adhesive joint includes a first part having a first surface and forming a first anti-peel feature including a first anti-peel surface, a second part having a second surface and forming a second anti-peel feature including a second anti-peel surface, and an adhesive disposed between the first and second surfaces and within the first and second anti-peel features. The adhesive connects the parts via adhesive bonds at the first and second surfaces and at the first and second anti-peel surfaces. The first and second anti-peel features are configured to load the adhesive bonds at the first and second anti-peel surfaces in shear stress when the fastenerless anti-peel adhesive joint is subjected to a peel force that is normal to the first and second surfaces such that the shear strength of the adhesive bonds at the first and second anti-peel surfaces prevents the parts from being peeled apart.

Abstract: Disclosed herein is an article comprising a first metal layer; a second metal layer that is chemically different from the first metal layer; and a third metal layer disposed between the first metal layer and the second metal layer and contacting both the first metal layer and the second metal layer; where the third metal layer is chemically similar to either the first metal layer or the second metal layer; where at least two metal layers that are chemically similar are welded together through a clearance opening located in a metal layer that is not chemically similar to the at least two metal layers.

Abstract: A method of injecting a liquid between a first panel and a second panel positioned flat against each other includes providing a tool defining an internal passageway having an inlet and an outlet. The first panel and the second panel are separated with the tool, to form a pocket between the first panel and the second panel, such that the outlet of the passageway is positioned in fluid communication with the pocket. A liquid source is connected to the inlet of the passageway to supply a liquid to the passageway. The liquid is injected into the pocket formed between the first panel and the second panel through the outlet of the passageway of the tool. The pocket is compressed or flattened to wet-out the liquid. The pocket may be compressed with the separating and injecting tool, or with a different device, such as a compressor or clamp.

Abstract: A system and method for bonding structures includes a method of bonding a first panel to a second panel. An adhesive material is applied to at least one of the first panel and the second panel and is disposed between the first panel and the second panel. A welding device having at least a first electrode and a second electrode is configured to receive and position the first panel and second panel between the first and second electrodes. The welding device generates an electric current with the first and second electrodes to apply to the first panel and the second panel. The electric current generates thermal energy having a first temperature that cures the adhesive material positioned between the first and second electrodes to bond the first panel with the second panel.

Abstract: An integrated amalgamation carrier can join parts. The integrated amalgamation carrier includes an amalgamation carrier body elongated along a longitudinal axis. In addition, the integrated amalgamation carrier includes a plurality of fasteners protruding from the amalgamation carrier body. The fasteners are integrated with the amalgamation body to form a one-piece structure.

Abstract: The indexing self-aligning hardware tool can join components and includes a first tool section including a die carrier, one or more dies coupled to the die carrier, and a first locator coupled to the die carrier. The indexing self-aligning hardware tool also includes a second tool section having a support body, one or more blankholders coupled to the support body, one or more punches movably disposed inside the blankholders, and a second locator coupled to the support body. The first locator and the second locator are configured to mate with a product feature locator of a component to align the first tool section relative to the second tool section.

Abstract: A multi-channel seat mounting wire retention bracket for a vehicle subjectable to an external force event and including a body structure and a seat having a seat mounting wire includes a body structure attachment portion and a wire retention portion. The body structure attachment portion is attachable to the body structure. The wire retention portion is configured to form a wire installation channel and a wire catch channel. The wire installation channel is configured to receive and retain the seat mounting wire when the seat is installed in the vehicle and to allow removal of the seat mounting wire when the seat is removed from the vehicle. The wire catch channel is configured to receive and retain the seat mounting wire during the external force event.

Abstract: A tether hook bracket for a vehicle subjectable to an external force event, followed by a rebound event, and having a body structure and a child seat connectable to the body structure via a tether having a tether hook includes a body structure attachment portion, a tether hook connection portion, and a tether hook rebound blocker portion. The body structure attachment portion is configured to be attachable to the body structure. The tether hook connection portion is configured to receive the tether hook, such that the tether hook is connected to the tether hook bracket. The tether hook rebound blocker portion is disposed between the body structure attachment portion and the tether hook connection portion and is configured to maintain the connection of the tether hook to the tether hook bracket when the vehicle is subjected to the rebound event.

Abstract: A tether hook bracket for a vehicle subjectable to an external force event, followed by a rebound event, and having a body structure and a child seat connectable to the body structure via a tether having a tether hook includes a body structure attachment portion, a tether hook connection portion, and a tether hook rebound blocker portion. The body structure attachment portion is configured to be attachable to the body structure. The tether hook connection portion is configured to receive the tether hook, such that the tether hook is connected to the tether hook bracket. The tether hook rebound blocker portion is disposed between the body structure attachment portion and the tether hook connection portion and is configured to maintain the connection of the tether hook to the tether hook bracket when the vehicle is subjected to the rebound event.

Abstract: An energy management system for a vehicle includes a load-bearing component operatively positioned in a wheel cavity rearward of a tire and wheel assembly in the wheel cavity. The load-bearing component is configured to limit movement of the tire and wheel assembly in the wheel cavity under a load applied to the vehicle forward of the tire and wheel assembly and offset from a longitudinal centerline of the vehicle.