Abstract: The invention provides a structural member of different materials having no different-material-bonded part between aluminum alloy material and steel material to be assembled. The structural member of different materials comprised of steel and aluminum alloy includes a first structural member including steel, and a second structural member having a part including steel and a part including aluminum alloy, the part including steel and the part including aluminum alloy being bonded by different-material bonding. The first structural member and the second structural member are bonded together only by bonding of steels between the part including steel of the second structural member and the first structural member.

Abstract: A target tubular member with flange, such as a bumper stay, has a flange having an outer diameter larger than the diameter of an axial section and is formed by electromagnetic forming without excessive expansion. The tubular member with flange includes an axial member made of a tubular aluminum alloy extrudate and a flange member joined to an end of the axial member. The axial member has an end flange being integrated at its end and having an area smaller than that of the flange member. The flange member has a hole, and a cylindrical hole flange at the edge of the hole. The axial member fits in the hole of the flange member, the end flange is in intimate contact with the flange member, and the outer periphery of a small-diameter portion of the axial member is in intimate contact with the inner periphery of the hole flange. The hole flange is held between the end flange and a protrusion.

Abstract: The bumper stay includes a cylindrical shaft member fit in to a hole of a bumper reinforce, a cylindrical reinforcing member fit in to the outer periphery of the shaft member in the rear side of the bumper reinforce, and a mounting flange member fit in to the outer periphery of the shaft member in its rear end. The shaft member is enlarged by electromagnetic forming and is tightly adhered to the inner peripheral surface of the hole formed in the bumper reinforce, the inner peripheral surface of the reinforcing member, and the inner peripheral surface of the hole flange formed in the mounting flange member, thereby these are joined with each other. Thin aluminum alloy extruded material can be used for the shaft member.

Abstract: The bumper system for a vehicle body includes a vehicle body bumper beam of a hollow construction with an impact buffer member arranged in the front side. The impact buffer member is provided with a collision wall part, side wall parts and joint flanges and is integrally formed by a metallic material, the collision wall part and the side wall parts forming a sectional shape of approximately U-shape which embraces the bumper beam. The joint flanges are joined with the flanges protruding from the rear wall of the bumper beam and support the impact buffer member from the rear wall side of the bumper beam.

Abstract: An automobile body reinforcement including a hollow aluminum alloy extrusion having an approximately rectangular cross-section is structured as follows: (a) a front wall, a rear wall, an upper horizontal wall, a lower horizontal wall, and an intermediate horizontal wall are provided; (b) the front and rear walls are each at least 3 mm thick; (c) the upper and lower horizontal walls divide each of the front and rear walls thereby defining upper and lower end portions of each of the front and rear walls as flange portions; and (d) the front wall has a concave portion formed in a middle portion thereof and the concave portion is connected to a front end of the intermediate wall.

Abstract: An automobile body reinforcement including a hollow aluminum alloy extrusion having an approximately rectangular cross-section is structured as follows: (a) a front wall, a rear wall, an upper horizontal wall, a lower horizontal wall, and an intermediate horizontal wall are provided; (b) the front and rear walls are each at least 3 mm thick; (c) the upper and lower horizontal walls divide each of the front and rear walls thereby defining upper and lower end portions of each of the front and rear walls as flange portions; and (d) the front wall has a concave portion formed in a middle portion thereof and the concave portion is connected to a front end of the intermediate wall.

Abstract: A target tubular member with flange, such as a bumper stay, has a flange having an outer diameter larger than the diameter of an axial section and is formed by electromagnetic forming without excessive expansion. The tubular member with flange includes an axial member made of a tubular aluminum alloy extrudate and a flange member joined to an end of the axial member. The axial member has an end flange being integrated at its end and having an area smaller than that of the flange member. The flange member has a hole, and a cylindrical hole flange at the edge of the hole. The axial member fits in the hole of the flange member, the end flange is in intimate contact with the flange member, and the outer periphery of a small-diameter portion of the axial member is in intimate contact with the inner periphery of the hole flange. The hole flange is held between the end flange and a protrusion.

Abstract: The invention provides a structural member of different materials having no different-material-bonded part between aluminum alloy material and steel material to be assembled. The structural member of different materials comprised of steel and aluminum alloy includes a first structural member including steel, and a second structural member having a part including steel and a part including aluminum alloy, the part including steel and the part including aluminum alloy being bonded by different-material bonding. The first structural member and the second structural member are bonded together only by bonding of steels between the part including steel of the second structural member and the first structural member.

Abstract: A target tubular member with flange, such as a bumper stay, has a flange having an outer diameter larger than the diameter of an axial section and is formed by electromagnetic forming without excessive expansion. The tubular member with flange includes an axial member made of a tubular aluminum alloy extrudate and a flange member joined to an end of the axial member. The axial member has an end flange being integrated at its end and having an area smaller than that of the flange member. The flange member has a hole, and a cylindrical hole flange at the edge of the hole. The axial member fits in the hole of the flange member, the end flange is in intimate contact with the flange member, and the outer periphery of a small-diameter portion of the axial member is in intimate contact with the inner periphery of the hole flange. The hole flange is held between the end flange and a protrusion.

Abstract: The bumper system for a vehicle body includes a vehicle body bumper beam of a hollow construction with an impact buffer member arranged in the front side. The impact buffer member is provided with a collision wall part, side wall parts and joint flanges and is integrally formed by a metallic material, the collision wall part and the side wall parts forming a sectional shape of approximately U-shape which embraces the bumper beam. The joint flanges are joined with the flanges protruding from the rear wall of the bumper beam and support the impact buffer member from the rear wall side of the bumper beam.

Abstract: There is provided a frame having closed cross-sections capable of preventing a welded joint of the frame from being turned in a wide open state, or being broken when an external force is applied to the frame at the time of vehicle collision, and so forth, and the frame is collapsed. The frame having closed cross-sections is provided with a body cylindrical in shape, wherein first side parts of a first frame member, in pairs, are welded to second side parts of a second frame member, in pairs, respectively, thereby forming a welded joint on both sides of the body, and respective end faces of each of the reinforcing plates, in the widthwise direction of the body, are butted against respective inner side faces of the side parts of the body, corresponding thereto.

Abstract: The bumper stay includes a cylindrical shaft member fit in to a hole of a bumper reinforce, a cylindrical reinforcing member fit in to the outer periphery of the shaft member in the rear side of the bumper reinforce, and a mounting flange member fit in to the outer periphery of the shaft member in its rear end. The shaft member is enlarged by electromagnetic forming and is tightly adhered to the inner peripheral surface of the hole formed in the bumper reinforce, the inner peripheral surface of the reinforcing member, and the inner peripheral surface of the hole flange formed in the mounting flange member, thereby these are joined with each other. Thin aluminum alloy extruded material can be used for the shaft member.

Abstract: A target tubular member with flange, such as a bumper stay, has a flange having an outer diameter larger than the diameter of an axial section and is formed by electromagnetic forming without excessive expansion. The tubular member with flange includes an axial member made of a tubular aluminum alloy extrudate and a flange member joined to an end of the axial member. The axial member has an end flange being integrated at its end and having an area smaller than that of the flange member. The flange member has a hole, and a cylindrical hole flange at the edge of the hole. The axial member fits in the hole of the flange member, the end flange is in intimate contact with the flange member, and the outer periphery of a small-diameter portion of the axial member is in intimate contact with the inner periphery of the hole flange. The hole flange is held between the end flange and a protrusion.

Abstract: A lightweight car body energy absorber made of Al alloy which provides a high energy absorption performance. The car body energy absorber comprises a hollow shape with a rectangular sectional profile and a reinforcing shape attached to the front face of the collision plane of the hollow shape, where the hollow shape and the reinforcing shape are aluminum alloy extruded shapes. The reinforcing shape has a hat-shaped open sectional profile, which is composed of a collision wall almost parallel to the collision plane of the hollow shape, plural mutually parallel horizontal ribs which support the collision wall, and vertical flanges provided at the tips of these ribs. The reinforcing shape is joined to the collision plane of the hollow shape through the vertical flanges.

Abstract: A lightweight car body energy absorber made of Al alloy which provides a high energy absorption performance. The car body energy absorber comprises a hollow shape 1 with a rectangular sectional profile and a reinforcing shape 2 attached to the front face of the collision plane of the hollow shape, where the hollow shape 1 and the reinforcing shape 2 are aluminum alloy extruded shapes. The reinforcing shape 2 has a hat-shaped open sectional profile, which is composed of a collision wall 6 almost parallel to the collision plane of the hollow shape 1, plural mutually parallel horizontal ribs 7a, 7b and 7c which support the collision wall 6, and vertical flanges 8a, 8b and 8c provided at the tips of these ribs. It is joined to the collision plane of the hollow shape 1 through the vertical flanges 8a, 8b and 8c.

Abstract: Sections 1 and 2 each in the form of a welded pipe (square pipe) are provided. The sections 1 and 2 are brought into abutment with each other so that the respective end faces 3a and 3b abut each other at a predetermined angle .beta. between each section and its axial direction. The sections 1 and 2 are arranged symmetrically with respect to each other. Acute end portions of the abutted portion are chamfered to from a plane part. Corners of the sections 1 and 2 are rounded. In such a combined state of both sections, the abutted portion is welded in the circumferential direction to form a weld bead. As a result, penetration of weld metal to the section 1 and that to the section 2 become equal to each other. Thus, it becomes possible to fabricate a welded structure having a uniform weld bead and having improved strength and reliability of welded portions.