Abstract: A method of assembling vehicle-body components includes positioning a first component on a second component. The first component has a different coefficient of thermal expansion than the second component and one of the first and second components defines a slot. The method also includes loosely installing a bolt though the slot and the first and second components, and creating a joint in the first and second components. The method further includes heating the first and second components, which causes the first and second components to move relative to each other due to thermal expansion in response to the heating. This movement causes the joint to fail. The method also includes tightening the bolt.

Abstract: A method and tool for calibrating an extruded tube for use in a manufacturing operation. According to the method, the tube is stretched while in a clamping tool by approximately 3%. The tool encloses the tube while a stretching mechanism is clamped to opposite longitudinal ends of the tube and applies a stretching force to opposite ends of the tube. The tool includes a clamping mechanism that clamps the tube into a cavity and a stretching mechanism with clamps that are attached to opposite longitudinal ends of the tube to calibrate the tube by longitudinally stretching the tube.

Abstract: Methods of processing an air-quenchable aluminum alloy component are provided. The method may include solution heat treating the component, air-quenching the component, and artificially aging the component to a yield strength of at least 200 MPa. The air-quenching may include cooling at a rate of 6° C./s to 25° C./s. The solution heat treatment may include heat treating the component at a temperature of 520° C. to 540° C. and the artificial aging step may include heat treating the component at 235° C. to 255° C. for 0.5 to 2 hours. The disclosed methods may produce a high strength (e.g., over 200 MPa) and high bendability (e.g., r/t ratio up to 0.3) component that does not significantly distort during the quenching process. The disclosed methods may be used to produce structural components having complex shapes, such as multiple, non-coplanar mating surface, while staying within predetermined tolerances.

Abstract: Forming a tailor-welded blank (TWB) having aluminum sheets includes various elements. For example, a hot-stamping methodology is applied to a welded blank for meeting load and stiffness requirements in tandem to weight efficiency. A TWB can result in improved material utilization, and applying the hot-stamping methodology can improve the formability of the TWB. After forming and subsequent processing, a peak-age heat treatment is utilized such that a lightweight, high strength part may be attained.

Abstract: A value stream process or method for forming vehicle rails from extruded aluminum tubes includes the steps of extruding an aluminum tube and hydroforming the extruded aluminum tube into a vehicle rail. More specifically, the method includes extruding the aluminum tube, bending the aluminum tube, preforming the aluminum tube, hydroforming the aluminum tube into a vehicle rail, trimming the vehicle rail to length and then artificially aging the rail followed by batch chemical pretreatment. In an alternative embodiment the artificial aging and batch chemical pretreatment processes are performed in reverse order. In either of the embodiments, localized induction annealing to recover formability may be performed between bending and preforming, between preforming and hydroforming or both.

Abstract: A reinforcement received between facing surfaces of adjacent panels that may be part of a hinge pillar of a vehicle such as a pickup truck and the panels may be aluminum. The reinforcement may be a one-piece molded structure. The reinforcement includes ribs that extend between the facing surfaces in a lattice arrangement defining a plurality of cells. The cells may have a number of transverse walls defining a perimeter of a polygon. The polygonal cells may have a facing wall on one side of the cell closing the cell. The facing wall may have an adhesive that is applied to the reinforcement and expanded in a paint bake oven to secure the reinforcement to the adjacent panels.

Abstract: An extruded aluminum alloy tube for hydroforming into an automotive body component includes a wall defining a closed perimeter. The wall includes weld seams disposed in the wall and running longitudinally along the tube. An extruded pip is disposed on the wall and runs longitudinally along the tube. The pip is parallel to the seams and is configured to identify a location of the seams for alignment of the tube during manufacturing.

Abstract: A finite-element-analysis simulator may simulate a pre-bend operation of an object design, performed to a raw material in forming an object, to produce simulated pre-bend results, adjust stress tensor components of the simulated pre-bend results to eliminate residual elastic deformation from the simulated pre-bend results, and complete object simulation of the raw material using the adjusted simulated pre-bend results.

Abstract: A method of hydroforming a vehicle rail from an extruded aluminum tube includes the steps of positioning the extruded aluminum tube into a hydroforming die and partially closing the hydroforming die. Next is the step of applying a liquid under a first level of pressure to the extruded aluminum tube in the hydroforming die. This is followed by engaging an inner radius of a bend in the extruded aluminum tube with the hydroforming die before completely closing the hydroforming die and increasing the level of liquid pressure in the workpiece to a second level to form and hydro-pierce a part from the extruded aluminum tube.

Abstract: A galling-resistive insert is positioned on an outer surface of a mandrel assembly. The insert is secured at the outer surface of the mandrel assembly and functions to reduce galling of an inner surface of a tubular blank during a rotary-draw bending operation.

Abstract: A method of processing high strength aluminum sheet is provided. The method may comprise uncoiling a coil of O or F-temper 6xxx or 7xxxx series aluminum alloy sheet, tailored rolling the sheet to form a tailored rolled sheet having at least two different thicknesses, blanking the tailored rolled sheet to form a tailored rolled blank (TRB), hot stamping the tailored rolled blank to form a component, and age hardening the component. The tailored rolling operation may reduce the thickness of the aluminum sheet by up to 60% in selected regions. The method may include a hot stamping process for age hardening aluminum alloys that solution heat treats and quenches the TRB. The method may be used to form lightweight, high-strength aluminum vehicle components having a controlled thickness profile to reduce component part weight.

Abstract: In at least one embodiment, an assembly is provided comprising a first member including a 6xxx series aluminum alloy heat treated to have a yield strength of at least 200 MPa and an r/t (bendability) ratio of up to 0.4. One or more members may be secured to the first member with a rivet (e.g., a self-piercing rivet). The heat treated alloy may have a yield strength of at least 260 MPa and may have a bendability ratio of up to 0.3. A method of forming an assembly is also provided, including heat treating a 6xxx series aluminum alloy to produce an alloy having a yield strength of at least 200 MPa and an r/t (bendability) ratio of up to 0.4 and riveting a member including the heat treated alloy to one or more additional members.

Abstract: A method of age hardening a 7xxx series aluminum alloy is provided that includes heat treating the alloy at a first temperature for a first exposure time and heat treating the alloy at a second temperature that is higher than the first temperature for a second exposure time. The age hardening process may be used to form an alloy having a yield strength of at least 490 MPa and the total age hardening time may be 8 hours or less. In one example, the first heat treatment is performed at 100° C. to 150° C. for 0.2 to 3 hours and the second heat treatment is be performed at 150° C. to 185° C. for 0.5 to 5 hours.

Abstract: A system and method of verifying that a part is heat treated to strengthen the part. The part is marked with a thermo-chromatic composition before heat treating. The part is then heat treated to strengthen the part and change the color of the thermo-chromatic composition to indicate successful completion of the heat treating process. A detector may act to prevent the inclusion of a non-heat treated part in an assembly by disabling an assembly tool. A controller may also provide data related to the completion of the heat treating process to be recorded in a database.

Abstract: A method and tool for calibrating an extruded tube for use in a manufacturing operation. According to the method, the tube is stretched while in a clamping tool by approximately 3%. The tool encloses the tube while a stretching mechanism is clamped to opposite longitudinal ends of the tube and applies a stretching force to opposite ends of the tube. The tool includes a clamping mechanism that clamps the tube into a cavity and a stretching mechanism with clamps that are attached to opposite longitudinal ends of the tube to calibrate the tube by longitudinally stretching the tube.

Abstract: A pressure sequence hydro-forming method is used to form an extruded structural tube. The extruded structural tube is placed in a hydro-forming die that is partially closed to compress the tube. The tube is filled with a hydro-forming liquid at a first pressure. The hydro-forming die is then closed and the pressure of the hydroforming fluid is increased as the hydro-forming die is fully closed. The pressure is increased to a second level of pressure to shape the tube into the desired part shape.

Abstract: A pressure sequence hydro-forming method is used to form an extruded structural tube. The extruded structural tube is placed in a hydro-forming die that is partially closed to compress the tube. The tube is filled with a hydro-forming liquid at a first pressure. The hydro-forming die is then closed and the pressure of the hydroforming fluid is increased as the hydro-forming die is fully closed. The pressure is increased to a second level of pressure to shape the tube into the desired part shape.

Abstract: An elevated temperature forming die apparatus comprising a lower die part having a first upper surface positioned to engage a lower surface of a first region of such a workpiece, an upper die part supported for reciprocal motion relative to the lower die part, the upper die part having a lower surface that engages an upper surface of a second region of a sheet material workpiece, heaters in thermal communication with the die parts, and a third die part having an upper surface that engages a lower surface of the second region of a sheet material workpiece whose first portion is positioned between the upper and lower die parts, the third die part being supported for reciprocal motion relative to the upper die part such that closure of the upper die part along the first stroke portion against the third die part will clamp the first portion of the workpiece between the upper and third die parts, and the third die part being supported for reciprocal motion relative to the lower die part such that, once the first p

Abstract: A superplastic forming apparatus and method for forming a sheet of material at an elevated temperatures into a workpiece having a complex geometry. The process takes advantage of a mechanical forming step, which draws material along a major axis to form a first preform. Upon completion of the first mechanical forming step, a second, initial superplastic forming step acts on the first preform to create a second preform having a plurality of channels or grooves located thereon. The grooves or channels function to draw additional material prior to the second or final gas forming step, which completes the forming process by driving the material against a forming surface. Accordingly, the method and apparatus function to reduce forming time and eliminate thinning and wrinkling of the sheet material during the forming process.

Abstract: An elevated temperature forming die apparatus comprising a lower die part having a first upper surface positioned to engage a lower surface of a first region of such a workpiece, an upper die part supported for reciprocal motion relative to the lower die part, the upper die part having a lower surface that engages an upper surface of a second region of a sheet material workpiece, heaters in thermal communication with the die parts, and a third die part having an upper surface that engages a lower surface of the second region of a sheet material workpiece whose first portion is positioned between the upper and lower die parts, the third die part being supported for reciprocal motion relative to the upper die part such that closure of the upper die part along the first stroke portion against the third die part will clamp the first portion of the workpiece between the upper and third die parts, and the third die part being supported for reciprocal motion relative to the lower die part such that, once the first p