Abstract: A method for tempering a workpiece is provided. The method includes providing a ferrous alloy workpiece having a martensite and/or bainite phase therein, heating at least a portion of the workpiece to a preselected temperature and then cooling the workpiece to a lower temperature. The preselected temperature is below the austensizing temperature of the alloy and the heating is accomplished in no more than 60 seconds. One embodiment of the present invention heats the workpiece using resistance heating.

Abstract: An apparatus for forming a metal article includes a station which receives and supports a workpiece. The station has a source of electrical current and a source of a fluid. The station further includes a first and a second electrode clamp. Each clamp is in electrical communication with the source of current and in fluid communication with the source of fluid. The clamps engage a workpiece and deliver an electrical current and a fluid thereto. The system includes an actuator mechanically associated with at least one of the clamps. The actuator is operable in combination with a clamp to apply mechanical force to the workpiece. The system is operable to selectably control the temperature profile and/or ambient conditions of a workpiece during forming or processing steps. Disclosed are specific systems including modular systems. Also disclosed are methods for using the systems.

Abstract: A method for providing a controlled heating profile in an article being heated in a resistance heating process is provided. The method includes contacting the article with a plurality of electrodes, selecting a first correlated group that includes at least two electrodes, and establishing a flow of electrical current between the electrodes of the first correlated group. The method also includes selecting a second correlated group that includes at least two electrodes, the second correlated group differing from the first correlated group. A flow of electrical current is also established between the electrodes of the second correlated group for the purpose of providing a controlled heating profile for an article undergoing resistance heating.

Abstract: A structural supporting roof pillar for use in a vehicle including an elongated, interiorly hollowed and polygonal shaped body having a selected arcuate lengthwise configuration and corresponding in placement to at least one of an A, B, and C vehicle pillar. A first component supporting flange is integrally formed, such as by overlapping end portions of a roll formed body, and projecting in at least a partially lengthwise extending fashion from a given cross sectional location. A secondary component supporting flange is affixed to a further cross sectional location associated with the body, such as further by welding.

Abstract: A continuous process for producing a shaped metal member from a feedstock comprising a flat web of metal includes a roll-forming station for shaping the web, a cutting station for cutting the shaped web into individual members, and a processing station for altering a physical characteristic of the metal comprising the members. The processing may include heat treating and/or shaping. The process may also be operable to carry out further operations such as marking, inspection, sorting and the like. Also disclosed is an apparatus for carrying out the process.

Abstract: An apparatus for forming a metal article includes a station which receives and supports a workpiece. The station has a source of electrical current and a source of a fluid. The station further includes a first and a second electrode clamp. Each clamp is in electrical communication with the source of current and in fluid communication with the source of fluid. The clamps engage a workpiece and deliver an electrical current and a fluid thereto. The system includes an actuator mechanically associated with at least one of the clamps. The actuator is operable in combination with a clamp to apply mechanical force to the workpiece. The system is operable to selectably control the temperature profile and/or ambient conditions of a workpiece during forming or processing steps. Disclosed are specific systems including modular systems. Also disclosed are methods for using the systems.

Abstract: An apparatus for forming a metal article includes a station which receives and supports a workpiece. The station has a source of electrical current and a source of a fluid. The station further includes a first and a second electrode clamp. Each clamp is in electrical communication with the source of current and in fluid communication with the source of fluid. The clamps engage a workpiece and deliver an electrical current and a fluid thereto. The system includes an actuator mechanically associated with at least one of the clamps. The actuator is operable in combination with a clamp to apply mechanical force to the workpiece. The system is operable to selectably control the temperature profile and/or ambient conditions of a workpiece during forming or processing steps. Disclosed are specific systems including modular systems. Also disclosed are methods for using the systems.

Abstract: A preselected metallurgical phase is formed in a body of a ferrous alloy by heating the workpiece to a temperature above an austenizing temperature of the alloy and thereafter contacting the workpiece with a quenching medium. Heat is input to the workpiece during at least a portion of the time it is in contact with the quenching medium. The quenching medium and/or the source of heat are regulated so that they work in combination to maintain the workpiece at a holding temperature which is above the temperature at which the martensite phase forms in the alloy. After maintaining the alloy at the holding temperature for a predetermined period of time, it is cooled to ambient. In particular implementations, the system operates to form a bainite phase in the alloy. Also disclosed are systems for implementing the method.

Abstract: A method for providing a controlled heating profile in an article being heated in a resistance heating process is provided. The method includes contacting the article with a plurality of electrodes, selecting a first correlated group that includes at least two electrodes, and establishing a flow of electrical current between the electrodes of the first correlated group. The method also includes selecting a second correlated group that includes at least two electrodes, the second correlated group differing from the first correlated group. A flow of electrical current is also established between the electrodes of the second correlated group for the purpose of providing a controlled heating profile for an article undergoing resistance heating. The electrical current between the electrodes of the second correlated group can be established after the flow of electrical current is established between the electrodes of the first correlated group.

Abstract: A system for delivering a coolant fluid to a workpiece has a reservoir for retaining the fluid, a pump for delivering fluid from the reservoir, a supply line in communication with the workpiece and a diverter valve. A bypass line is in communication with the diverter valve, and the valve may be utilized to deliver fluid from the reservoir to the workpiece or to bypass the workpiece and circulate fluid back to the reservoir. The system also includes a fluid return line for conveying fluid from the workpiece back to the reservoir.

Abstract: A frame system for a motor vehicle includes a plurality of frame members each having a connector socket defined therein. The system further includes a connector having an outer profile configured to engage the sockets of two of the frame members so as to connect them in a fixed angular relationship. The connectors are composite bodies including a core member and an exterior body which covers at least a portion of the core member and defines a portion of the outer profile of the connector. Also disclosed are frames which employ the system and methods for manufacturing the frames.

Abstract: A method for tempering a workpiece is provided. The method includes providing a ferrous alloy workpiece having a martensite and/or bainite phase therein, heating at least a portion of the workpiece to a preselected temperature and then cooling the workpiece to a lower temperature. The preselected temperature is below the austensizing temperature of the alloy and the heating is accomplished in no more than 60 seconds. One embodiment of the present invention heats the workpiece using resistance heating.

Abstract: A structural supporting roof pillar for use in a vehicle including an elongated, interiorly hollowed and polygonal shaped body having a selected arcuate lengthwise configuration and corresponding in placement to at least one of an A, B, and C vehicle pillar. A first component supporting flange is integrally formed, such as by overlapping end portions of a roll formed body, and projecting in at least a partially lengthwise extending fashion from a given cross sectional location. A secondary component supporting flange is affixed to a further cross sectional location associated with the body, such as further by welding.

Abstract: A frame system for a motor vehicle includes a plurality of frame members each having a connector socket defined therein. The system further includes a connector having an outer profile configured to engage the sockets of two of the frame members so as to connect them in a fixed angular relationship. The connectors are composite bodies including a core member and an exterior body which covers at least a portion of the core member and defines a portion of the outer profile of the connector. Also disclosed are frames which employ the system and methods for manufacturing the frames.

Abstract: A bainite phase is formed in a body of a ferrous alloy by heating the workpiece to a temperature above an austenizing temperature of the alloy and thereafter contacting the workpiece with a quenching medium. Heat is input to the workpiece during at least a portion of the time it is in contact with the quenching medium. The quenching medium and/or the source of heat are regulated so that they work in combination to maintain the workpiece at a holding temperature which is no more than 350° C. but above the temperature at which the martensite phase forms in the alloy. After maintaining the alloy at the holding temperature for a predetermined period of time, it is cooled to ambient. Also disclosed are systems for implementing the method.

Abstract: An apparatus for forming a metal article includes a station which receives and supports a workpiece. The station has a source of electrical current and a source of a fluid. The station further includes a first and a second electrode clamp. Each clamp is in electrical communication with the source of current and in fluid communication with the source of fluid. The clamps engage a workpiece and deliver an electrical current and a fluid thereto. The system includes an actuator mechanically associated with at least one of the clamps. The actuator is operable in combination with a clamp to apply mechanical force to the workpiece. The system is operable to selectably control the temperature profile and/or ambient conditions of a workpiece during forming or processing steps. Disclosed are specific systems including modular systems. Also disclosed are methods for using the systems.

Abstract: A forming system for shaping a metal article includes a pair of die members having a welding station associated therewith. The die members are operative to shape a workpiece disposed therebetween, and the welding station carries out welding operation on the article. The die members may be part of a die quench set which shapes and quenches a heated article. Welding may take place before, during, or after the shaping and quenching steps. Also disclosed are methods and specific apparatus for carrying out the invention.

Abstract: A system for delivering a coolant fluid to a workpiece has a reservoir for retaining the fluid, a pump for delivering fluid from the reservoir, a supply line in communication with the workpiece and a diverter valve. A bypass line is in communication with the diverter valve, and the valve may be utilized to deliver fluid from the reservoir to the workpiece or to bypass the workpiece and circulate fluid back to the reservoir. The system also includes a fluid return line for conveying fluid from the workpiece back to the reservoir.

Abstract: A continuous process for producing a shaped metal member from a feedstock comprising a flat web of metal includes a roll-forming station for shaping the web, a cutting station for cutting the shaped web into individual members, and a processing station for altering a physical characteristic of the metal comprising the members. The processing may include heat treating and/or shaping. The process may also be operable to carry out further operations such as marking, inspection, sorting and the like. Also disclosed is an apparatus for carrying out the process.