Abstract: A welded assembly includes a first component including an aluminum material, a second component including a stainless steel, and a third component including a steel material. An ultrasonic weld is formed between the first and second components to join them and form a stack. A sealant and/or adhesive may be applied to the stack. A resistance spot weld is used to join the third component to the stack to form the welded assembly. The resistance spot weld encompasses a portion of the first, second, and third components, and a portion of the ultrasonic weld. The resistance spot weld is completely encompassed in the welded assembly, and thus is sealed from electrolyte in a surrounding environment.

Abstract: A vehicle includes a frame including a front frame part and a rear frame part. An elongated single wheel is rotatably connected to one of the front frame part and the rear frame part. The elongated wheel houses an expansion device including a linkage mechanism adapted to reconfigure a shape of the elongated wheel between a cylindrical shape in top view of the vehicle when the vehicle is traveling in a straight direction and a frustoconical shape in top view of the vehicle in a turning condition of the vehicle.

Abstract: A multiple spot vaporizing foil actuator weld (VFAW) system includes a target sheet layer secured relative to a stabilizing component, such that standoff components may be arranged sandwichably between the target and a flier sheet layer. An electrically insulating layer separates the flier from a vaporizing component sheet layer, which may comprise at least two vaporizing subsections configured to have less conductive material than at least three dividing subsections that separate the vaporizing subsections. The geometry and/or other features of the vaporizing subsections may be varied to optimize the vaporization. A second electrically insulated stabilizing component may sandwichably secure the above components between the first stabilizing component in order to control the forces generated in the VFAW process. The method involves loading the vaporizable component sheet layer with electrons via applied voltage such that the vaporizing subsections sublimate.

Abstract: A welded assembly includes a first component including an aluminum material, a second component including a stainless steel, and a third component including a steel material. An ultrasonic weld is formed between the first and second components to join them and form a stack. A sealant and/or adhesive may be applied to the stack. A resistance spot weld is used to join the third component to the stack to form the welded assembly. The resistance spot weld encompasses a portion of the first, second, and third components, and a portion of the ultrasonic weld. The resistance spot weld is completely encompassed in the welded assembly, and thus is sealed from electrolyte in a surrounding environment.

Abstract: A method for welding a stack of sheets having a plurality of sheets of different materials is provided. In an aspect, the stack of sheets includes an aluminum sheet and a galvanneal steel sheet. In an aspect, the method includes resistively spot welding the galvanneal sheet to a hot-stamped steel sheet placed between the aluminum sheet and the galvanneal sheet, the sheet of hot-stamped steel including stress relief sections. The method further includes placing a metal foil on the aluminum sheet and vaporizing the metal foil to project portions of the aluminum sheet through the stress relief sections of the hot-stamped steel sheet to weld the portions of the aluminum sheet to the galvanized steel sheet. In another aspect, the method includes placing the metal foil on a raised portion of the aluminum sheet and projecting the raised portion of the aluminum onto the galvanneal steel sheet.

Abstract: A vehicle steering assembly and method for steering a vehicle includes an array of electromagnets fixed relative to the vehicle, and a charged plate that is moveable with respect to the array and connected to a wheel that determines the travel direction of the vehicle. When activated, the electromagnets produce a charge that is opposite that of the charged plate, thus attracting the charged plate. The electromagnets are selectively activated to move a centroid of a charged region about the array to thereby move the charged plate in a desired direction. Movement of the charged plate causes a corresponding movement of the wheel to which it is connected. Movement of the wheel thus establishes a travel direction for the vehicle.

Abstract: A vehicle includes a frame including a front frame part and a rear frame part. A single front wheel is rotatably connected to the front frame part. A single rear wheel is rotatably connected to the rear frame part. Each of the front wheel and the rear wheel is adapted to have a cylindrical shape in top view when the vehicle is traveling in a straight direction, and at least one of the front wheel and the rear wheel is adapted to expand and have a frustoconical shape in top view in a turning condition of the vehicle.

Abstract: A system and method for joining multiple lightweight metal sheets to a steel sheet through friction welding that include rotating and moving a first fastener along a fastener axis towards a first workpiece, wherein the first workpiece includes a lightweight metal sheet. The system and method also include contacting the first workpiece and driving the first fastener through the first workpiece and a second workpiece. The system and method further include joining the second fastener and completing friction welding.

Abstract: A vehicle includes a frame including a front frame part and a rear frame part. An elongated single wheel is rotatably connected to one of the front frame part and the rear frame part.

Abstract: A method for welding a stack of sheets having a plurality of sheets of different materials is provided. In an aspect, the stack of sheets includes an aluminum sheet and a galvanneal steel sheet. In an aspect, the method includes resistively spot welding the galvanneal sheet to a hot-stamped steel sheet placed between the aluminum sheet and the galvanneal sheet, the sheet of hot-stamped steel including stress relief sections. The method further includes placing a metal foil on the aluminum sheet and vaporizing the metal foil to project portions of the aluminum sheet through the stress relief sections of the hot-stamped steel sheet to weld the portions of the aluminum sheet to the galvanized steel sheet. In another aspect, the method includes placing the metal foil on a raised portion of the aluminum sheet and projecting the raised portion of the aluminum onto the galvanneal steel sheet.

Abstract: A vehicle frame construction or frame assembly and method for assembling a multi-material vehicle frame includes a first frame member formed of a first metal material and a second frame member formed of a second metal material that is dissimilar to the first metal material. The second frame member is joined to the first frame member via vaporizing foil actuator welding (VFAW).

Abstract: A vehicle steering assembly and method for steering a vehicle includes an array of electromagnets fixed relative to the vehicle, and a charged plate that is moveable with respect to the array and connected to a wheel that determines the travel direction of the vehicle. When activated, the electromagnets produce a charge that is opposite that of the charged plate, thus attracting the charged plate. The electromagnets are selectively activated to move a centroid of a charged region about the array to thereby move the charged plate in a desired direction. Movement of the charged plate causes a corresponding movement of the wheel to which it is connected. Movement of the wheel thus establishes a travel direction for the vehicle.

Abstract: A vehicle frame construction or frame assembly and method for assembling a multi-material vehicle frame includes a first frame member formed of a first metal material and a second frame member formed of a second metal material that is dissimilar to the first metal material. The second frame member is joined to the first frame member via vaporizing foil actuator welding (VFAW).

Abstract: A vehicle includes a frame including a front frame part and a rear frame part. A single front wheel is rotatably connected to the front frame part. A single rear wheel is rotatably connected to the rear frame part. Each of the front wheel and the rear wheel is adapted to have a cylindrical shape in top view when the vehicle is traveling in a straight direction, and at least one of the front wheel and the rear wheel is adapted to expand and have a frustoconical shape in top view in a turning condition of the vehicle.

Abstract: A method for welding a stack of sheets having a plurality of sheets of different materials is provided. In an aspect, the stack of sheets includes an aluminum sheet and a galvanneal steel sheet. In an aspect, the method includes resistively spot welding the galvanneal sheet to a hot-stamped steel sheet placed between the aluminum sheet and the galvanneal sheet, the sheet of hot-stamped steel including stress relief sections. The method further includes placing a metal foil on the aluminum sheet and vaporizing the metal foil to project portions of the aluminum sheet through the stress relief sections of the hot-stamped steel sheet to weld the portions of the aluminum sheet to the galvanized steel sheet. In another aspect, the method includes placing the metal foil on a raised portion of the aluminum sheet and projecting the raised portion of the aluminum onto the galvanneal steel sheet.

Abstract: An apparatus for determining alignment of a wheel mounted to a vehicle includes a plate, a housing and a light source. The plate has a top surface, a bottom surface, and an outer perimeter. The bottom surface is substantially planar and the outer perimeter includes an engagement portion. The plate is configured such that it may be positioned at least partially within a wheel rim, with the engagement portion and the bottom surface contacting interior circumferential and interior annular surfaces of the wheel rim, respectively, and with the bottom surface substantially perpendicular to the wheel rotational axis. The housing is attached to the top surface of the plate and defines a chamber. The light source is supported at least partially within the chamber and is configured to project light away from the housing. Methods are also provided for manufacturing a vehicle and for inspecting a wheel mounted upon a vehicle.

Abstract: An apparatus for determining alignment of a wheel mounted to a vehicle includes a plate, a housing and a light source. The plate has a top surface, a bottom surface, and an outer perimeter. The bottom surface is substantially planar and the outer perimeter includes an engagement portion. The plate is configured such that it may be positioned at least partially within a wheel rim, with the engagement portion and the bottom surface contacting interior circumferential and interior annular surfaces of the wheel rim, respectively, and with the bottom surface substantially perpendicular to the wheel rotational axis. The housing is attached to the top surface of the plate and defines a chamber. The light source is supported at least partially within the chamber and is configured to project light away from the housing. Methods are also provided for manufacturing a vehicle and for inspecting a wheel mounted upon a vehicle.

Abstract: A method is provided for measuring impact toughness of a tie rod end through use of a pendulum-type impact testing machine. The method includes attaching a first member of the tie rod end with respect to a base of the pendulum-type impact testing machine. The pendulum-type impact testing machine is operated such that the hammer impacts the second member of the tie rod end. Force arising from the impact of the hammer upon the second member of the tie rod end is measured. A support apparatus is also provided for supporting the tie rod end in a position to receive contact from the hammer of the pendulum-type impact testing machine.

Abstract: A method is provided for measuring impact toughness of a tie rod end through use of a pendulum-type impact testing machine. The method includes attaching a first member of the tie rod end with respect to a base of the pendulum-type impact testing machine. The pendulum-type impact testing machine is operated such that the hammer impacts the second member of the tie rod end. Force arising from the impact of the hammer upon the second member of the tie rod end is measured. A support apparatus is also provided for supporting the tie rod end in a position to receive contact from the hammer of the pendulum-type impact testing machine.