Abstract: A three-dimensional object may be manufactured using a powder bed fusion additive manufacturing technique. A layer of powder feed material may be distributed over a solid substrate and scanned with a high-energy laser beam to locally melt selective regions of the layer and form a pool of molten feed material. The pool of molten feed material may be exposed to gaseous nitrogen, carbon, or boron to respectively dissolve nitride, carbide, or boride ions into the pool of molten feed material to produce a molten nitrogen, carbon, or boron-containing solution. The molten nitrogen, carbon, or boron-containing solution may cool and solidify into a solid layer of fused nitride, carbide, or boride-containing material.

Abstract: An alloy composition is provided. The alloy composition includes silicon (Si) at a concentration of greater than or equal to about 0.55 wt. % to less than or equal to about 0.75 wt. %, magnesium (Mg) at a concentration of greater than or equal to about 0.55 wt. % to less than or equal to about 0.75 wt. %, chromium (Cr) at a concentration of greater than or equal to about 0.15 wt. % to less than or equal to about 0.3 wt. %, and a balance of the alloy composition being aluminum (Al). The alloy composition has an intermetallic phase content of less than or equal to about 3 wt. %. Methods of preparing the alloy composition and of processing the alloy composition are also provided.

Abstract: An alloy composition is provided. The alloy composition includes silicon (Si) at a concentration of greater than or equal to about 0.55 wt. % to less than or equal to about 0.75 wt. %, magnesium (Mg) at a concentration of greater than or equal to about 0.55 wt. % to less than or equal to about 0.75 wt. %, chromium (Cr) at a concentration of greater than or equal to about 0.15 wt. % to less than or equal to about 0.3 wt. %, and a balance of the alloy composition being aluminum (Al). The alloy composition has an intermetallic phase content of less than or equal to about 3 wt. %. Methods of preparing the alloy composition and of processing the alloy composition are also provided.

Abstract: An alloy composition is provided. The alloy composition includes silicon (Si) at a concentration of greater than or equal to about 0.55 wt. % to less than or equal to about 0.75 wt. %, magnesium (Mg) at a concentration of greater than or equal to about 0.55 wt. % to less than or equal to about 0.75 wt. %, chromium (Cr) at a concentration of greater than or equal to about 0.15 wt. % to less than or equal to about 0.3 wt. %, and a balance of the alloy composition being aluminum (Al). The alloy composition has an intermetallic phase content of less than or equal to about 3 wt. %. Methods of preparing the alloy composition and of processing the alloy composition are also provided.

Abstract: A panel assembly is formed by a plurality of bonds between two sheet materials in a face to face relationship to form a preform. The plurality of bonds define a closed perimeter region between the two sheet materials and an open perimeter region between the two sheet materials. The preform may be formed into a predefined shape. Pressurized fluid is applied through an inlet into the open perimeter region to expand the preform. The pressurized fluid expands the open perimeter region such that the two sheet materials expand in an opposing direction, thereby defining an expanded open perimeter region. The closed perimeter region between the two sheet materials remains vacant of the pressurized fluid such that the closed perimeter region is not expanded. The expanded open perimeter region is filled with a filler material for improving a performance characteristic of the panel assembly, e.g., strength, sound absorption, or stiffness.

Abstract: A three-dimensional object may be manufactured using a powder bed fusion additive manufacturing technique. A layer of powder feed material may be distributed over a solid substrate and scanned with a high-energy laser beam to locally melt selective regions of the layer and form a pool of molten feed material. The pool of molten feed material may be exposed to gaseous nitrogen, carbon, or boron to respectively dissolve nitride, carbide, or boride ions into the pool of molten feed material to produce a molten nitrogen, carbon, or boron-containing solution. The molten nitrogen, carbon, or boron-containing solution may cool and solidify into a solid layer of fused nitride, carbide, or boride-containing material.

Abstract: A three-dimensional object made of a bulk nitride, carbide, or boride-containing material may be manufactured using a powder bed fusion additive manufacturing technique. A layer of powder feed material may be distributed over a solid substrate and scanned with a high-energy laser beam to locally melt selective regions of the layer and form a pool of molten feed material. The pool of molten feed material may be exposed to gaseous nitrogen, carbon, or boron to respectively dissolve nitride, carbide, or boride ions into the pool of molten feed material to produce a molten nitrogen, carbon, or boron-containing solution. The molten nitrogen, carbon, or boron-containing solution may cool and solidify into a solid layer of fused nitride, carbide, or boride-containing material. In one form, the three-dimensional object may comprise a permanent magnet made up of a plurality of solid layers of fused iron nitride material having a magnetic Fe16N2 phase.

Abstract: An alloy composition is provided. The alloy composition includes silicon (Si) at a concentration of greater than or equal to about 0.55 wt. % to less than or equal to about 0.75 wt. %, magnesium (Mg) at a concentration of greater than or equal to about 0.55 wt. % to less than or equal to about 0.75 wt. %, chromium (Cr) at a concentration of greater than or equal to about 0.15 wt. % to less than or equal to about 0.3 wt. %, and a balance of the alloy composition being aluminum (Al). The alloy composition has an intermetallic phase content of less than or equal to about 3 wt. %. Methods of preparing the alloy composition and of processing the alloy composition are also provided.

Abstract: A three-dimensional object made of a bulk nitride, carbide, or boride-containing material may be manufactured using a powder bed fusion additive manufacturing technique. A layer of powder feed material may be distributed over a solid substrate and scanned with a high-energy laser beam to locally melt selective regions of the layer and form a pool of molten feed material. The pool of molten feed material may be exposed to gaseous nitrogen, carbon, or boron to respectively dissolve nitride, carbide, or boride ions into the pool of molten feed material to produce a molten nitrogen, carbon, or boron-containing solution. The molten nitrogen, carbon, or boron-containing solution may cool and solidify into a solid layer of fused nitride, carbide, or boride-containing material. In one form, the three-dimensional object may comprise a permanent magnet made up of a plurality of solid layers of fused iron nitride material having a magnetic Fe16N2 phase.

Abstract: A method of forming a part from a blank includes positioning the blank within a forming die. Water is introduced between the blank and the forming die. The water is heated to form steam between the blank and the forming die. The blank is reshaped within the forming die to form the part while the steam is disposed between the blank and the forming die. The steam forms a cushion between the blank and the forming die to reduce friction therebetween. A lubricant is not applied to the blank prior to being positioned in the forming die. Therefore, the formed part does not require a washing step after being formed.

Abstract: Methods suitable for forming complex parts from work-hardened sheet materials of limited formability are described. The formability of the work-hardened sheet is enhanced by forming at elevated temperature. The forming temperature is preferably selected to minimally undo the effects of work hardening so that the formed part is of higher strength than a like part formed from an annealed sheet. The method is applicable to age-hardening and non-age-hardening aluminum and magnesium alloys.

Abstract: A panel assembly is formed by a plurality of bonds between two sheet materials in a face to face relationship to form a preform. The plurality of bonds define a closed perimeter region between the two sheet materials and an open perimeter region between the two sheet materials. The preform may be formed into a predefined shape. Pressurized fluid is applied through an inlet into the open perimeter region to expand the preform. The pressurized fluid expands the open perimeter region such that the two sheet materials expand in an opposing direction, thereby defining an expanded open perimeter region. The closed perimeter region between the two sheet materials remains vacant of the pressurized fluid such that the closed perimeter region is not expanded. The expanded open perimeter region is filled with a filler material for improving a performance characteristic of the panel assembly, e.g., strength, sound absorption, or stiffness.

Abstract: A panel assembly is formed by a plurality of bonds between two sheet materials in a face to face relationship to form a preform. The plurality of bonds define a closed perimeter region between the two sheet materials and an open perimeter region between the two sheet materials. The preform may be formed into a predefined shape. Pressurized fluid is applied through an inlet into the open perimeter region to expand the preform. The pressurized fluid expands the open perimeter region such that the two sheet materials expand in an opposing direction, thereby defining an expanded open perimeter region. The closed perimeter region between the two sheet materials remains vacant of the pressurized fluid such that the closed perimeter region is not expanded. The expanded open perimeter region is filled with a filler material for improving a performance characteristic of the panel assembly, e.g., strength, sound absorption, or stiffness.

Abstract: A method of forming a part from a blank includes positioning the blank within a forming die. Water is introduced between the blank and the forming die. The water is heated to form steam between the blank and the forming die. The blank is reshaped within the forming die to form the part while the steam is disposed between the blank and the forming die. The steam forms a cushion between the blank and the forming die to reduce friction therebetween. A lubricant is not applied to the blank prior to being positioned in the forming die. Therefore, the formed part does not require a washing step after being formed.

Abstract: A panel assembly is formed by a plurality of bonds between two sheet materials in a face to face relationship to form a preform. The plurality of bonds define a closed perimeter region between the two sheet materials and an open perimeter region between the two sheet materials. The preform may be formed into a predefined shape. Pressurized fluid is applied through an inlet into the open perimeter region to expand the preform. The pressurized fluid expands the open perimeter region such that the two sheet materials expand in an opposing direction, thereby defining an expanded open perimeter region. The closed perimeter region between the two sheet materials remains vacant of the pressurized fluid such that the closed perimeter region is not expanded. The expanded open perimeter region is filled with a filler material for improving a performance characteristic of the panel assembly, e.g., strength, sound absorption, or stiffness.

Abstract: Methods suitable for forming complex parts from work-hardened sheet materials of limited formability are described. The formability of the work-hardened sheet is enhanced by forming at elevated temperature. The forming temperature is preferably selected to minimally undo the effects of work hardening so that the formed part is of higher strength than a like part formed from an annealed sheet. The method is applicable to age-hardening and non-age-hardening aluminum and magnesium alloys.

Abstract: A hemming station is configured for hemming a panel assembly including an outer panel having a hem flange defined by a hem edge. The hemming station includes a roller configured to fold the hem flange, a heating device configured to heat the hem edge, and a control unit. The control unit is configured to control the roller and the heating device such that the roller folds the hem flange when the temperature of the hem edge is in a predetermined temperature range.

Abstract: One embodiment includes a lightweight automotive vehicle door construction including an inner panel partially formed from a lightweight metal casting. The casting provides a toe pan, hinge pillar and beltline. A lightweight stamping connected with the casting provides a remainder of the inner skin. The stamping provides an opposite pillar and latch mount. A header connected to the casting along a first end and with the beltline at a second end provides a window frame. A side intrusion beam extends between the hinge pillar and the opposite pillar. An outer panel is connected with the inner panel.

Abstract: A magnesium alloy comprising up to about six weight percent zinc and up to about one weight percent cerium may be hot worked to produce an intermediate or final alloy workpiece that exhibits enhanced ductility and strength at room temperature. The addition of zinc and a small amount of cerium may affect the magnesium alloy by increasing strength and ductility, and improving the work hardening behavior.

Abstract: A hemming station is configured for hemming a panel assembly including an outer panel having a hem flange defined by a hem edge. The hemming station includes a roller configured to fold the hem flange, a heating device configured to heat the hem edge, and a control unit. The control unit is configured to control the roller and the heating device such that the roller folds the hem flange when the temperature of the hem edge is in a predetermined temperature range.