Gm Global Technolgoy Operations, Inc.

Charles J Bruggemann

Joseph M Lendway, Iv

Sanjay Mahasukhlal Shah

Chi-Mou Ni

Hesham Ahmed Ezzat

David A Gatny

Michael R Webb

Michael Gerard Poss

Pei-chung Wang

Spyros Pete Mellas

Chongmin Kim

Peter M Parlow

John D Fickes

Wuhua Yang

Daniel C Hutchinson

Alexander D Khakhalev

Robert R Mayer

Wallace T Hall

Michael L Wenner

Tuan A Ngo

Carl W Robinson

Wihua Yang

William Henry Todd, Jr

Tasnim Hassan

Paul A Benton

Mark Goebel

A joining operation for a stack of three metal sheets performed using only a single welding step, with access to only one sheet side being required. An inner sheet of the stack has formed therein a pair of bifurcated projections, wherein at least one first apex faces in one direction and at least one second apex faces in the opposite direction. First and second outer metal sheets are assembled with the inner sheet, wherein the first outer sheet abuts the at least one first apex, and the second outer sheet abuts the at least one second apex. A projection welding apparatus welds the sheets, using only access to the first outer sheet superposed the bifurcated projections, wherein a majority of the current flows through the second outer sheet.

Method for one-sided, one step joining of a metal sheet stack

A method includes acquiring a first structural component conforming to a design, producing a first vehicle including the first structural component, and transferring possession of the first vehicle with the first structural component having a first set of mechanical properties. The method further includes acquiring a second structural component conforming to the design, subjecting the second structural component to a heat treatment process so that the second structural component is characterized by a second set of mechanical properties different from the first set of mechanical properties, producing a second vehicle including the second structural component, and transferring possession of the second vehicle with the second structural component having the second set of mechanical properties.

Method of varying material properties

A method is provided for manufacturing a shaped tubular part from a first tube and second tube. The end of the first tube is inserted into the end of the second tube to provide a region of overlapping tube walls. An induction coil is placed around the outer surface of the first and second tubes at the region of overlapped tube walls. The induction coil is energized to make a plurality of longitudinally spaced apart magnetic pulse welds attaching the tubes together to thereby form a multi-tube one-piece composite tubular assembly. The tubular assembly is then subjected to a forming process such as hydroforming, tube bending or stretch bending to form the final shape of the tubular part.

Method for manufacture of shaped tubular part

A method is provided for forming a complexly-shaped tubular structure such as a tapered pillar or other structure for a vehicle body. A sheet metal blank having a longitudinal axis is rolled about the longitudinal axis to form a tubular shape and the side edges of the blank are then welded together to form a tube. The tube is then enclosed in a hydroforming die and pressurized to conform the tube to the shape of the die and thereby form the desired complex shape. The sheet metal blank may be formed by the end-to-end welding together of a plurality of separate sheet metal blanks that differ from one another in characteristic including material thickness, material alloy composition, and/or coating. One or more of the blanks can have side edges that are non-parallel so that the tube will taper in diameter along its length.

Method for forming a complex-shaped tubular structure

A hydroformed dovetail joint and method of joining tubular members includes a first hydroformed tubular member having a depression therein and a second hydroformed tubular member having an end. The end of the second hydroformed tubular member is disposed over the depression of the first hydroformed tubular member to join the first hydroformed tubular member and the second hydroformed tubular member together to form a dovetail joint between the first hydroformed tubular member and the second hydroformed tubular member.

Method of joining hydroformed tubular members

A method of making a variable thickness tubular member for a vehicle includes the steps of providing a tubular member and positioning a mandrel inside of the tubular member. The method also includes the steps of hydroforming the tubular member into a variable thickness tubular member having a variable wall thickness along its perimeter.

Method of making variable thickness tubular member for vehicles

A hydroformed tubular member and method of hydroforming the hydroformed tubular member for a vehicle includes the steps of providing a tubular blank and positioning the tubular blank within a die. The method also includes the steps of hydroforming the tubular blank in the die into a tubular member having a generally 'T' shape with a sidewall having a straight length of the sidewall increased from its originally expanded length.

Hydroformed tubular members and method of hydroforming tubular members for vehicles

A hydroformed and roll-formed cross sill assembly for a vehicle and method of making same includes a pair of hydroformed tubular side members. The hydroformed and roll-formed cross sill assembly also includes a roll-formed beam member disposed between the tubular side members and at least one weld to secure the beam member to each of the tubular side members.

Hydroformed and roll-formed cross sill assembly for vehicles and method of making same

A method is provided for attaching together a larger tube and a smaller tube in a T-shaped intersecting joint. A hole is formed in the larger tube with a flange surrounding the hole. A circumferential extending flange is formed on the outside of the smaller tube. Adhesive is placed on either the outside of the smaller tube or the inside of the flange of the larger tube. The smaller tube is inserted into the hole in the larger tube so that the adhesive is interposed between the inside of the flange of the larger tube and the outside of the smaller tube and the flange on the outside of the smaller tube comes into electrical conducting contact with the flange of the larger tube. Electrical current is applied to flow between the large tube and the small tube so that electrical resistance heating is obtained to cure the adhesive.

Method for attaching intersecting tubes

A door beam arrangement is provided for a vehicle door having a door panel with a hinge mounting flange and a latch mounting flange. A first hollow tube of high-strength steel has one end fixedly mounted on one of the flanges, and a second end. A second hollow tube of a non-ferrous material has one end fixedly mounted on the other of the flanges and is of smaller diameter than the first hollow tube and inserted into the first hollow tube and is slidable therein to accommodate variations in the distance between the hinge mounting flange and the latch mounting flange.

Door beam for motor vehicle

A structural assembly for a vehicle and method of making same includes a hydroformed tubular member extending axially, a reinforcement disposed within and generally perpendicular to an axis of the tubular member, and at least one securement to secure the reinforcement to the tubular member.

Structural assembly for vehicles and method of making same

A method of forming a tubular member with thickened ends includes the steps of positioning a tubular member between open die halves and sealing ends of the tubular member. The method also includes the steps of applying at least nominal internal hydraulic pressure to the tubular member and progressively closing the die halves. The method includes the steps of raising the hydraulic pressure substantially within the tubular member to expand and conform the tubular member to the tubular cavity portion. The method further includes the steps of thickening a wall thickness of the axial ends of the tubular member, separating the die halves, and removing the tubular member having thickened axial ends from the die.

Method of forming thickened tubular members

A method of joining tubular members together includes the steps of providing an internal tubular member, providing an external tubular member, and heating the external tubular member and/or cooling the internal tubular member. The method also includes the steps of joining the internal tubular member and second tubular member together to form an overlap region of a joined tubular member, and positioning the joined tubular member between open die halves mating with one another to define a tubular cavity portion. The method includes the steps of progressively closing the die halves to progressively deform the joined tubular member within the tubular cavity portion. The method includes the steps of applying hydraulic pressure to expand and conform the joined tubular member to the tubular cavity portion. The method also includes the steps of separating the die halves and removing the expanded joined tubular member from the die.

Method of joining tubular members

A multi-section support rail has a first section with an outer circumferential wall, a parallel inner circumferential wall and a transverse web extending longitudinally therealong, a second section hollow tubular section with an outer circumferential wall and a parallel inner circumferential wall. The outer circumferential walls are substantially identical dimensionally. The sections are joined at mating surfaces,. The joined sections are pre-bent at the second section and then hydroformed to a final desired shape. The transverse web retains the extruded dimensions throughout the hydroforming process.

Multi-section support rail apparatus and method of making

A multi-section support rail has a first section with an outer circumferential wall, a parallel inner circumferential wall and a transverse web extending longitudinally therealong, a second section hollow tubular section with an outer circumferential wall and a parallel inner circumferential wall. The outer circumferential walls are substantially identical dimensionally. The sections are joined at mating surfaces. The joined sections are pre-bent at the second section and then hydroformed to a final desired shape. The transverse web retains the extruded dimensions throughout the hydroforming process.

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Rochester Hills, MI, United States of America

Charles J Bruggemann