Abstract: A method of manufacturing metallic components consisting of at least two different materials, one of them being an iron-based alloy and the other an aluminum-based alloy, and involving the steps of: depositing a metallic layer onto the body made from the iron-based alloy, said layer being an aluminum-based alloy, preferably based on Al—Si or Fe, placing the coated body in a casting mold and casting an aluminum-based alloy about the coated body. Prior to placing the body in the casting mold, the metallic layer of the body is sprayed and/or blasted with silicon powder and/or Borax (Na2B4O7—10H2O, hydrated sodium borate).

Abstract: A method of securing body panels to a space frame of a vehicle is disclosed. Body panels are secured to rivet nuts that are assembled to frame members. The location of the rivet nuts or rivet nuts supporting surface is measured and the rivet nuts are milled or machined to correspond to reference body coordinates. The rivet nuts function as a integral shim pack and obviate the need for shims between the space frame and body panels. The rivet nuts may be milled or formed to predetermined thicknesses before or after assembly to the frame.

Abstract: A method of manufacturing metallic components consisting of at least two different materials, one of them being an iron-based alloy and the other an aluminum-based alloy, and involving the steps of: depositing a metallic layer onto the body made from the iron-based alloy, said layer being an aluminum-based alloy, preferably based on Al—Si or Fe, placing the coated body in a casting mold and casting an aluminum-based alloy about the coated body. Prior to placing the body in the casting mold, the metallic layer of the body is sprayed and/or blasted with silicon powder and/or Borax (Na2B4O7—10H2O, hydrated sodium borate).

Abstract: A method of securing body panels to a space frame of a vehicle is disclosed. Body panels are secured to rivet nuts that are assembled to frame members. The location of the rivet nuts or rivet nuts supporting surface is measured and the rivet nuts are milled or machined to correspond to reference body coordinates. The rivet nuts function as a integral shim pack and obviate the need for shims between the space frame and body panels. The rivet nuts may be milled or formed to predetermined thicknesses before or after assembly to the frame.

Abstract: One aspect of the present invention is a method of applying a solder filler to an aluminum body part. The method includes abrading the surface of an aluminum body part at a temperature of at least about 300 degrees Celsius with a solder filler at a temperature of at least about 300 degrees Celsius.

Abstract: A crush rail or other structural member of a vehicle is provided with crush triggers. The crush triggers are formed by heating localized areas of the crush rail or other part and allowing them to cool slowly to provide increased ductility and reduced strength in a localized region. The crush rail is designed to collapse in a series of convolutions in a regular and repeated pattern. Crush triggers may be provided on body pillars, steering columns, drive shafts, engine support cradles, and other parts of a vehicle. A plurality of crush triggers may be provided on a single structural member depending upon impact absorption requirements.