Abstract: Methods and systems are provided for generating a mold. In one embodiment, a method includes: determining, by a processor, a fiber orientation for a plurality of points in a part; determining, by the processor, a distortion value based on the fiber orientations; and generating, by the processor, mold dimensions based on the distortion values.

Abstract: A method and associated device for joining a first workpiece to a second workpiece employing a vibration welder includes placing the first and second workpieces in a lapped arrangement and interposing an adhesive material between contiguous surfaces of the first and second workpieces. A first compressive load is applied to a spot welding locus associated with the lapped arrangement of the first and second workpieces, and then relaxed. A second compressive load is applied to the lapped arrangement of the first and second workpieces simultaneous with applying, via a vibration welder, a vibrational excitation to the spot welding locus associated with the lapped arrangement of the first and second workpieces. The applied vibrational excitation is discontinued, and the second compressive load continues to be applied to the spot welding locus associated with the lapped arrangement of the first and second workpieces for a period of time subsequent thereto.

Abstract: A method and associated device for joining a first workpiece to a second workpiece employing a vibration welder includes placing the first and second workpieces in a lapped arrangement and interposing an adhesive material between contiguous surfaces of the first and second workpieces. A first compressive load is applied to a spot welding locus associated with the lapped arrangement of the first and second workpieces, and then relaxed. A second compressive load is applied to the lapped arrangement of the first and second workpieces simultaneous with applying, via a vibration welder, a vibrational excitation to the spot welding locus associated with the lapped arrangement of the first and second workpieces. The applied vibrational excitation is discontinued, and the second compressive load continues to be applied to the spot welding locus associated with the lapped arrangement of the first and second workpieces for a period of time subsequent thereto.

Abstract: Methods and systems are provided for generating a mold. In one embodiment, a method includes: determining, by a processor, a fiber orientation for a plurality of points in a part; determining, by the processor, a distortion value based on the fiber orientations; and generating, by the processor, mold dimensions based on the distortion values.

Abstract: A pillar for a vehicle includes a translucent polymer composite having chopped reinforcing fibers incorporated therein. The pillar also includes a truss embedded in the translucent polymer composite and disposed substantially along a length of the pillar. The truss and the translucent polymer composite share a loading condition applied to the pillar. The pillar is to be disposed between a lower body portion of the vehicle and a roof of the vehicle to support the roof.

Abstract: A pillar for a vehicle includes a translucent polymer composite having chopped reinforcing fibers incorporated therein. The pillar also includes a truss embedded in the translucent polymer composite and disposed substantially along a length of the pillar. The truss and the translucent polymer composite share a loading condition applied to the pillar. The pillar is to be disposed between a lower body portion of the vehicle and a roof of the vehicle to support the roof.

Abstract: Methods of joining a magnesium substrate to a second substrate are provided. A region of the magnesium substrate and a region of the second substrate are aligned to provide an overlap. A region of the overlap is deformed to provide a joint. A polymeric material is disposed in the joint to secure together the magnesium substrate and the second substrate. The joining of the magnesium substrate and the second substrate is facilitated by using a die in various aspects.

Abstract: A composite material is disclosed that includes a matrix binder material and a plurality of elongated fiber strands. The strands have a longitudinally extending central portion having two or more lobes extending radially from the central portion and disposed longitudinally along the strand.

Abstract: A method of manufacturing a non-ferrous, light metal alloy vibration-damped part for a vehicle chassis includes introducing a polymer insert into a cavity formed in the part. The polymer insert may be introduced into the cavity by separately fabricating the polymer insert and then sliding or maneuvering the insert into the cavity or by injecting a liquid polymer material into the cavity and then solidifying and shrinking the liquid polymer material into the polymer insert. The vibration-damped light metal alloy part can damp vibrations that originate within or are imparted to the part when such vibrations effectuate relative contacting frictional movement between an exterior surface of the polymer insert and an interior surface of the cavity.

Abstract: A method is disclosed for forming corrosion-resistant joints in a plurality of overlapping thin metal sheet workpieces, at least one of which comprises at least 85% by weight of magnesium sheets. The fastener is a fiber-reinforced polymer rod shaped and sized for insertion into a coaxial opening formed in each sheet and subsequently upset on each end to form a head. The workpiece sheets are deformed to form mechanically-interfering features which cooperatively complement the strength of the fastener, under at least some joint loading patterns. The method may be used for other workpiece and fastener compositions.

Abstract: Methods of joining a magnesium substrate to a second substrate are provided. A region of the magnesium substrate and a region of the second substrate are aligned to provide an overlap. A region of the overlap is deformed to provide a joint. A polymeric material is disposed in the joint to secure together the magnesium substrate and the second substrate. The joining of the magnesium substrate and the second substrate is facilitated by using a die in various aspects.

Abstract: A method of manufacturing a non-ferrous, light metal alloy vibration-damped part for a vehicle chassis includes introducing a polymer insert into a cavity formed in the part. The polymer insert may be introduced into the cavity by separately fabricating the polymer insert and then sliding or maneuvering the insert into the cavity or by injecting a liquid polymer material into the cavity and then solidifying and shrinking the liquid polymer material into the polymer insert. The vibration-damped light metal alloy part can damp vibrations that originate within or are imparted to the part when such vibrations effectuate relative contacting frictional movement between an exterior surface of the polymer insert and an interior surface of the cavity.

Abstract: A shape memory polymer workpiece is attached to a second workpiece. A face of the SMP workpiece is placed against an attachment surface of the second workpiece. The second workpiece has an attachment hole(s). The SMP workpiece is activated (e.g., heated) to a softening temperature and a portion extruded into the attachment hole of the facing surface of the second workpiece. The SMP piece is held while still heated against the second workpiece, the material flowing as result of the shape memory effect to form an attachment. As the SMP material cools while still under load its modulus increases fixing the attachment geometry. Reheating the attached parts without pushing them together reverses the process.

Abstract: A method is disclosed for forming corrosion-resistant joints in a plurality of overlapping thin metal sheet workpieces, at least one of which comprises at least 85% by weight of magnesium sheets. The fastener is a fiber-reinforced polymer rod shaped and sized for insertion into a coaxial opening formed in each sheet and subsequently upset on each end to form a head. The workpiece sheets are deformed to form mechanically-interfering features which cooperatively complement the strength of the fastener, under at least some joint loading patterns. The method may be used for other workpiece and fastener compositions.

Abstract: One side of a metal sheet is joined to a polymer layer by applying heat to a joining area on the opposite side of the metal. The heat flows through the thin metal to activate a thermoplastic material or heat setting polymer into a bond with the metal. The method can be used to bond the metal sheet to a plastic body or another metal member. It is preferred to use a friction or friction stir tool to heat the metal surface.

Abstract: A composite floor pan may be joined with other structural members of an automotive vehicle. External loads imparted to the structural members may be transferred to the floor pan. The floor pan may be configured to absorb and/or transfer these external loads without separating.

Abstract: One side of a metal sheet is joined to a polymer layer by applying heat to a joining area on the opposite side of the metal. The heat flows through the thin metal to activate a thermoplastic material or heat setting polymer into a bond with the metal. The method can be used to bond the metal sheet to a plastic body or another metal member. It is preferred to use a friction or friction stir tool to heat the metal surface.

Abstract: In an assembly of facing metal sheets separated by a polymer layer, welded metallurgical bonds are formed between the metal sheets by use of a friction stir weld tool. A rotating tool penetrates the first sheet, locally displaces the encountered portion of polymer film and penetrates into the second sheet. The affected metal of the two sheets is momentarily plasticized and stirred, and the plasticized metal of the two sheets combines to form a weld between the metal sheets. The interposed polymer film may be intended to serve as an adhesive or a vibration damping medium or the like. The facing metal sheets can be layers of facing laminated metal sheet structures that each comprise two metal sheets bonded by an adhesive interlayer.

Abstract: A composite floor pan may be joined with other structural members of an automotive vehicle. External loads imparted to the structural members may be transferred to the floor pan. The floor pan may be configured to absorb and/or transfer these external loads without separating.

Abstract: One side of a metal sheet is joined to a polymer layer by applying heat to a joining area on the opposite side of the metal. The heat flows through the thin metal to activate a thermoplastic material or heat setting polymer into a bond with the metal. The method can be used to bond the metal sheet to a plastic body or another metal member. It is preferred to use a friction or friction stir tool to heat the metal surface.