Abstract: A stamped part includes a first blank, a second blank, and a weld joining the first blank to the second blank. The weld includes opposing ends. At least one of the opposing ends of the weld is recessed from adjacent edges of the first and second blanks.

Abstract: A stamped part includes a first blank, a second blank, and a weld joining the first blank to the second blank. The weld includes opposing ends. At least one of the opposing ends of the weld is recessed from adjacent edges of the first and second blanks.

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 method of forming a stamped part includes forming a tailor welded blank by friction stir welding (FSW) a first blank to a second blank, removing a FSW start spot and a FSW stop spot from the tailor welded blank using a machining process such that a finished tailor welded blank is formed and stamping the finished tailor welded blank into the stamped part such that a weld formed by FSW the first blank to the second blank is plastically deformed. The first blank and the second blank can be aluminum alloy blanks and a predetermined amount of material is machined from the FSW start spot and the FSW stop spot, the predetermined amount of material being equal to or greater than a thickness of the first blank and the second blank.

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 details assemblies for mounting and supporting components within battery packs. Exemplary battery packs may include a first battery array, a second battery array positioned adjacent to the first battery array, a crossmember positioned between the first battery array and the second battery array, and a support bracket connected to the crossmember. Together, the crossmember and the support bracket established an assembly. Both the first battery array and the second battery array may be secured to the crossmember, and the support bracket may support a second tier structure above at least one of the first battery array or the second battery array.

Abstract: An apparatus and method, according to an exemplary aspect of the present disclosure includes, among other things, a battery tray configured to support a plurality of battery cells and at least one cross member positioned between adjacent battery cells. The at least one cross member comprises a base portion that is fixed to the battery tray and an elongated body extending outwardly from the base portion. The elongated body extends from a first end at the base portion to a second end that is opposite the first end, and wherein the first end has a first width and the second end has a second width that is less than the first width.

Abstract: A method of forming a stamped part includes forming a tailor welded blank by friction stir welding (FSW) a first blank to a second blank, removing a FSW start spot and a FSW stop spot from the tailor welded blank using a machining process such that a finished tailor welded blank is formed and stamping the finished tailor welded blank into the stamped part such that a weld formed by FSW the first blank to the second blank is plastically deformed. The first blank and the second blank can be aluminum alloy blanks and a predetermined amount of material is machined from the FSW start spot and the FSW stop spot, the predetermined amount of material being equal to or greater than a thickness of the first blank and the second blank.

Abstract: An apparatus and method, according to an exemplary aspect of the present disclosure includes, among other things, a battery support structure to support a plurality of battery cells, wherein the battery support structure includes opposing longitudinal sides and opposing lateral sides. A first extrusion is positioned to extend along at least one of the opposing longitudinal and lateral sides. A second extrusion is connected to the first extrusion such that the first extrusion is located between the plurality of battery cells and the second extrusion.

Abstract: An apparatus and method, according to an exemplary aspect of the present disclosure includes, among other things, a battery tray configured to support a plurality of battery cells and at least one cross member positioned between adjacent battery cells. The at least one cross member comprises a base portion that is fixed to the battery tray and an elongated body extending outwardly from the base portion. The elongated body extends from a first end at the base portion to a second end that is opposite the first end, and wherein the first end has a first width and the second end has a second width that is less than the first width.

Abstract: This disclosure details assemblies for mounting and supporting components within battery packs. Exemplary battery packs may include a first battery array, a second battery array positioned adjacent to the first battery array, a crossmember positioned between the first battery array and the second battery array, and a support bracket connected to the crossmember. Together, the crossmember and the support bracket established an assembly. Both the first battery array and the second battery array may be secured to the crossmember, and the support bracket may support a second tier structure above at least one of the first battery array or the second battery array.

Abstract: A vehicle assembly includes a first member including a first side and a second side. The vehicle assembly includes a coupler extending from the first side to the second side, the first side and the second side being crimped to the coupler. The vehicle assembly includes a second member and a fastener fastening the first member and the second member to the coupler.

Abstract: A vehicle assembly includes a first member including a first side and a second side. The vehicle assembly includes a coupler extending from the first side to the second side, the first side and the second side being crimped to the coupler. The vehicle assembly includes a second member and a fastener fastening the first member and the second member to the coupler.

Abstract: A first method is disclosed for forming a tubular reinforcement that comprises the steps of: providing a 7xxx aluminum tube, heating tube to at least 450° C. and water quenching the tube in less than or equal to 20 seconds after heating. All of the forming processes on the tube are then completed from within 1 to 8 hours of quenching. A second method for forming a tubular reinforcement is disclosed that comprises the steps of providing a 7xxx-O temper aluminum tube and forming the tube into a predetermined shape. The tube in then heated the tube to at least 450° C. and quenched the tube with water or air in a hydroforming die just prior to or while hydroforming the tube.

Abstract: A truck box assembly including a sidewall, a pair of doors, and a support assembly is provided. The sidewall may define an opening to provide clearance for a wheel house. Each of the pair of doors extends from one side of the opening. The support assembly may be mounted to a truck box and support the sidewall as the sidewall moves between retracted and expanded positions. Each of the doors may be moveable between an open position and a closed position filling the opening in the expanded position. The support assembly may include a mount post secured to the truck box at a standard interface plate (SIP) bracket and a horizontal member extending from the mount post and secured to the truck box at a stake pocket hole.

Abstract: A truck box assembly including a sidewall, a pair of doors, and a support assembly is provided. The sidewall may define an opening to provide clearance for a wheel house. Each of the pair of doors extends from one side of the opening. The support assembly may be mounted to a truck box and support the sidewall as the sidewall moves between retracted and expanded positions. Each of the doors may be moveable between an open position and a closed position filling the opening in the expanded position. The support assembly may include a mount post secured to the truck box at a standard interface plate (SIP) bracket and a horizontal member extending from the mount post and secured to the truck box at a stake pocket hole.

Abstract: Semi-tubular self-piercing rivets and solid rivets are provided with surface features such as recesses or lobes. The recesses or lobes engage the panels that are joined by the rivet to prevent rotation of one or both panels after rivet insertion. The recesses or lobes may be provided at the head end or tip end of the rivet or may be provided at both the head end and the tip end of the rivet.

Abstract: A tailgate pivotally mountable to a vehicle includes a tailgate body comprising first and second sidewalls, and a strainer disposed between the first and second walls and extending in a longitudinal orientation. The tailgate further includes a stake pocket disposed between the first and second sidewalls and extending substantially orthogonal to the strainer. The stake pocket includes a channel body defining an interior channel.

Abstract: A first method is disclosed for forming a tubular reinforcement that comprises the steps of: providing a 7xxx aluminum tube, heating tube to at least 450° C. and water quenching the tube in less than or equal to 20 seconds after heating. All of the forming processes on the tube are then completed from within 1 to 8 hours of quenching. A second method for forming a tubular reinforcement is disclosed that comprises the steps of providing a 7xxx-O temper aluminum tube and forming the tube into a predetermined shape. The tube in then heated the tube to at least 450° C. and quenched the tube with water or air in a hydroforming die just prior to or while hydroforming the tube.

Abstract: A tailgate pivotally mountable to a vehicle includes a tailgate body comprising first and second sidewalls, and a strainer disposed between the first and second walls and extending in a longitudinal orientation. The tailgate further includes a stake pocket disposed between the first and second sidewalls and extending substantially orthogonal to the strainer. The stake pocket includes a channel body defining an interior channel.