Abstract: An upset protrusion joining gun for joining two parts together by forging a protrusion of one part that extends through an opening in the other part to form a boss that extends over a portion of the other part surrounding the opening.

Abstract: An upset protrusion joining gun for joining two parts together by forging a protrusion of one part that extends through an opening in the other part to form a boss that extends over a portion of the other part surrounding the opening.

Abstract: A method of coupling a plurality of parts together includes casting a first part to include a base and a protrusion that protrudes from the base. The first part is made from a metallic material. The method also includes providing a second part with an opening and mating the first and second parts such that the protrusion is received within the opening. Moreover, the method includes deforming the protrusion over the second part such that the second part is retained between the deformed protrusion and the base of the first part.

Abstract: A spare tire carrier for a vehicle may structurally entail a base, a mounting flange extending from the base, a vertical support post extending from the base, a light support post attached to the vertical support post, a threaded stud that engages a front surface of the base to support a spare tire. A tether, which may be secured to the base with a fastener, may lie largely concealed within the base and have additional studs or bolts which may protrude through a front surface of the base and further support a spare tire. A plurality of strength ribs may join the mounting flange and the base, while the base, the first mounting flange, vertical support post extending from the base, and plurality of strength ribs may be a single cast magnesium part. The tether may be of another high strength material.

Abstract: A spare tire carrier for a vehicle may structurally entail a base, a mounting flange extending from the base, a vertical support post extending from the base, a light support post attached to the vertical support post, a threaded stud that engages a front surface of the base to support a spare tire. A tether, which may be secured to the base with a fastener, may lie largely concealed within the base and have additional studs or bolts which may protrude through a front surface of the base and further support a spare tire. A plurality of strength ribs may join the mounting flange and the base, while the base, the first mounting flange, vertical support post extending from the base, and plurality of strength ribs may be a single cast magnesium part. The tether may be of another high strength material.

Abstract: A friction stir welding method where a friction stir welding device is moved through a plurality of points that form an essentially conical shape as the device engages substrates to be welded to form a mechanical interlocking structure at an interface between the substrates.

Abstract: A hybrid resistance heating/ultrasonic welding method is used to join substrates. The resistance heating sufficiently softens or melts the substrates at an interface, and an ultrasonic wave is used solid state bond the substrates at the interface. The hybrid method can be used for both spot welding as well as continuous welding.

Abstract: A lightweight automobile body structure is provided and includes a base assembly including an upper sheet and a lower sheet. The upper sheet has first and second series of upper reliefs formed therein and the lower sheet has first and second series of lower reliefs formed therein. The upper and lower sheets stacked adjacent one another, whereby the first series of upper reliefs are in flush contact with the first series of lower reliefs and the second series of upper reliefs are offset from the second series of lower reliefs for defining a space therebetween. First and second side panels are fixedly attached to the base assembly and extend therefrom for defining respective sides. A roof panel is fixedly attached between the first and second side panels for defining a roof.