Abstract: A billet of an aluminum alloy or magnesium alloy is formed by a combination of forming operations into a desired article of complex, but open shape. In a first step a billet is heated and extruded to form an extruded workpiece profile having at least first and second sections of different thicknesses. The extruded workpiece may be shaped so that the respective sections are at an angle to each other. The extruded workpiece is then further formed against a forming surface so that the shape of least one of the sections is further formed toward the shape of the article. The methods are suitable for efficient manufacture of many like complex shapes such as brackets and reinforcement members, and even container pans for computers and other electronic devices.

Abstract: An assembly for limiting corrosion between a first member made of a first material and a second member made of a second material, different from the first material, includes a plurality of cylindrical dimples defined in the first member. The cylindrical dimples are formed as a one-piece structure with the first member. The cylindrical dimples and the second member interact to define a plurality of galvanic contact zones. An electrocoat covers substantially all of the first member and the second member, but does not cover the galvanic contact zones. Therefore, the galvanic contact zones are not in contact with the electrocoat and are sealed to prevent contact with an electrolyte. A method of assembling a first member to a second member, to limit corrosion therebetween, is also provided.

Abstract: One exemplary embodiment of a method includes removing an automotive part from a stretch forming machine. The method also includes spraying a coolant over at least a portion of an exterior surface of the automotive part in order to cool the automotive part to a lower temperature so that the automotive part is nonmalleable and is not as susceptible to the forces of gravity as it might otherwise be.

Abstract: A billet of an aluminum alloy or magnesium alloy is formed by a combination of forming operations into a desired article of complex, but open shape. In a first step a billet is heated and extruded to form an extruded workpiece profile having at least first and second sections of different thicknesses. The extruded workpiece may be shaped so that the respective sections are at an angle to each other. The extruded workpiece is then further formed against a forming surface so that the shape of least one of the sections is further formed toward the shape of the article. The methods are suitable for efficient manufacture of many like complex shapes such as brackets and reinforcement members, and even container pans for computers and other electronic devices.