Abstract: A number of variations may include a product including an extruded support beam constructed and arranged to be used as an inner support for a vehicle end gate.

Abstract: A structural panel includes a closed-cell foam core formed of a metallic material; a first carbon-fiber panel bonded to a first side of the closed-cell foam core; and a second carbon-fiber panel bonded to a second side of the closed-cell foam core such that the foam core is disposed between the first carbon-fiber panel and the second carbon-fiber panel.

Abstract: A method of and attachment system for securing and manipulating attractive objects upon an interior vehicular surface, utilizing at least one coded magnet to selectively attach/retain the objects, and provide various other functions, including aiding in alignment, orientation, and retrieval of the objects, and activating an associated sub-system.

Abstract: A number of variations may include a product including an extruded support beam constructed and arranged to be used as an inner support for a vehicle end gate.

Abstract: A method of and attachment system for securing and manipulating attractive objects upon an interior vehicular surface, utilizing at least one coded magnet to selectively attach/retain the objects, and provide various other functions, including aiding in alignment, orientation, and retrieval of the objects, and activating an associated sub-system.

Abstract: A method of integrally forming a composite rib structure includes positioning a first fiber sheet on a pre-preg mold, the pre-preg mold including a first channel and a second channel separated by a wedge-shaped protrusion, and the fiber sheet including a plurality of fibers oriented along a first common direction. The method further including extending the wedge-shaped protrusion through the first fiber sheet such that a subset of the plurality of fibers are displaced about the protrusion and into each of the respective first channel and second channel; applying a resin within each of respective first channel and second channel to the plurality of fibers; pre-curing the resin to form a pre-preg rib structure within the channels; and removing the pre-preg rib structure from the pre-preg mold.

Abstract: A method of isolating a metallic fastener from a carbon-fiber composite panel includes inserting the metallic fastener within an electrically isolating annular collar; inserting the metallic fastener and electrically isolating annular collar within a hole defined by the carbon-fiber composite panel; and securing the metallic fastener to the carbon-fiber composite panel. The annular collar may be circumferentially disposed about the metallic fastener such that the annular collar separates and electrically isolates the entire metallic fastener from the carbon-fiber composite panel. As such, the annular collar may minimize the galvanic reaction between the fastener and the carbon-fiber composite panel.

Abstract: A method of forming a hole in a composite panel includes positioning a first fiber sheet on a layup table, where the layup table has a forming tool extending outward from a portion of the table, and the fiber sheet includes a plurality of fibers oriented along a first common direction. The method further includes extending the forming tool through the first fiber sheet such that a subset of the plurality of fibers are displaced about the forming tool: applying a resin to the sheet of fibers; pre-curing the resin to form a pre-preg part defining a hole about the forming tool; and removing the pre-preg part from the layup table.

Abstract: A method of imparting superior fatigue performance to a vehicle wheel cast from a magnesium alloy by selective application of friction stir processing to regions of the casting known to be subject to high in-service stresses is described. The method may be particularly applicable to open wheel designs in which a plurality of spokes is used to connect the hub and rim portions of the wheel.

Abstract: A structural panel includes a closed-cell foam core formed of a metallic material; a first carbon-fiber panel bonded to a first side of the closed-cell foam core; and a second carbon-fiber panel bonded to a second side of the closed-cell foam core such that the foam core is disposed between the first carbon-fiber panel and the second carbon-fiber panel.

Abstract: A method of forming a casting includes providing a preform to a mold cavity. The preform is formed from one of a first metal and a second metal and defines an interface surface. A molten portion of the other of the first metal and the second metal is cast into the mold such that the molten portion proximately contacts the interface surface of the preform. An interface layer at the interface surface, a first portion defined by the mold cavity and the interface layer, and a second portion defined by the interface layer, are formed during casting. The interface layer may define a metallurgical bond between the first portion and the second portion. In the non-limiting example provided herein, the first portion is substantially comprised of aluminum and the second portion is substantially comprised of magnesium. In a non-limiting example, the casting may be configured as a vehicle wheel.

Abstract: A method of forming a casting includes providing a preform to a mold cavity. The preform is formed from one of a first metal and a second metal and defines an interface surface. A molten portion of the other of the first metal and the second metal is cast into the mold such that the molten portion proximately contacts the interface surface of the preform. An interface layer at the interface surface, a first portion defined by the mold cavity and the interface layer, and a second portion defined by the interface layer, are formed during casting. The interface layer may define a metallurgical bond between the first portion and the second portion. In the non-limiting example provided herein, the first portion is substantially comprised of aluminum and the second portion is substantially comprised of magnesium. In a non-limiting example, the casting may be configured as a vehicle wheel.

Abstract: A method for stamping a desired shape from a sheet blank includes providing the sheet blank. The method also includes locally cooling the sheet blank with a stream of fluid in a predetermined area of high stress concentration to be experienced during forming of the sheet blank into a desired shape. The method additionally includes forming the metal sheet blank into the desired shape in a stamping press with a punch. A system employing the method for forming a sheet blank is also disclosed.

Abstract: A magnetic bumper apparatus for constraining a vehicle closure to a vehicle closure interface includes first and second magnetic members configured for attachment to the closure and closure interface, and a non-magnetic bumper element interposed therebetween. Each magnetic member defines a plurality of spatially modulated magnetic fields (SMMF) in corresponding patterns to provide a cumulative SMMF attractive force and a cumulative SMMF repulsive force between the magnetic members and define a separation reference and an alignment reference. The magnetic members in magnetic proximity to each other constrain the closure to the closure interface with respect to the alignment and separation references to prevent contact between a closure surface and a closure interface surface and to define at least one alignment parameter therebetween.

Abstract: A method for enhancing the formability of press-formed high strength, age-hardenable aluminum alloy sheet is disclosed. The sheet is partially formed when in an overaged condition, for example in a T7 or T8 temper condition, to form a preform. After an annealing and solutionizing process the preform is promptly further deformed in a second forming operation and subsequently aged to develop high strength. The method may be employed to form components of more complex shape from higher strength aluminum alloys such as 6000 series and 7000 series alloys.

Abstract: A method and system for forming a part from a workpiece including a hollow portion, using a mandrel and a conventional press such as a stamping press includes filling the hollow portion of the workpiece with a mandrel material and transforming the mandrel material to form a mandrel. The mandrel material is removable from the formed part and may be recycled to form a mandrel for another workpiece.

Abstract: A magnetic spring utilizing spatially modulated magnetic field patterns of magnetic regions for both stator and slider, allowing custom force curves over the range of motion. Also disclosed is a magnetic spring whose slider can be rotated relative to the stator on the axis, such that the alignment of the spatially modulated magnetic field patterns of the slider and the stator is altered, resulting in changeable force curve for the spring, selected by rotating the slider.

Abstract: A magnetic bumper apparatus for constraining a vehicle closure to a vehicle closure interface includes first and second magnetic members configured for attachment to the closure and closure interface, and a non-magnetic bumper element interposed therebetween. Each magnetic member defines a plurality of spatially modulated magnetic fields (SMMF) in corresponding patterns to provide a cumulative SMMF attractive force and a cumulative SMMF repulsive force between the magnetic members and define a separation reference and an alignment reference. The magnetic members in magnetic proximity to each other constrain the closure to the closure interface with respect to the alignment and separation references to prevent contact between a closure surface and a closure interface surface and to define at least one alignment parameter therebetween.

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: A vehicle hood or a panel covering an object includes an inner surface and an outer surface. The inner surface faces the object and is offset from the object by a basin depth. The outer surface is substantially opposite the inner surface. A local energy absorber is operatively attached to the inner surface or is disposed between the inner surface and the object. The local energy absorber has a singly-connected structure, which includes a first wall portion and a second wall portion. The first wall portion is operatively attached to the inner surface. The singly-connected structure also includes a curved connector portion joining the first wall portion and the second wall portion.