Gm Global Technolgoy Operations, Inc.

John E Carsley

Richard Murray Kleber

John Robert Bradley

Gary A Kruger

Anil Kumar Sachdev

Chih-Cheng Hsu

Hamid Ghavami Kia

Paul Edward Krajewski

James Gregory Schroth

Richard Harry Hammar

James C O'Kane

Raja K Mishra

Nelson T Brinas

Rajesh Raghavan

Susan Elizabeth Hartfield-Wunsch

Gary R Pelowski

Theresa M Lee

Mark William Verbrugge

David R Sigler

Blair E Carlson

Wayne Cai

Elisabeth Jane Berger

Yang-Tse Cheng

Chen-Shih Wang

John Neal Owens

Mike M Ghiran

Xiaohong Gayden

Yen-Lung Chen

Chongmin Kim

Albert H Butlin, Jr

Mark G Konopnicki

Sampath K Vanimisetti

Valentin Schultheis

Stuart J Brown

Gerald Edward Sokol

Louis J Conrad

Stephan Fell

Kevin K Parkila

Kenneth G Danaj

Stephen R Koshorek

Jacob Lyjak

Ce Sun

Stewart T Edmison

George L Kilbertus

George K Nurminen

Jeffrey M Scramlin

John T Carter

Hui-Min Huang

Methods suitable for forming complex parts from work-hardened sheet materials of limited formability are described. The formability of the work-hardened sheet is enhanced by forming at elevated temperature. The forming temperature is preferably selected to minimally undo the effects of work hardening so that the formed part is of higher strength than a like part formed from an annealed sheet. The method is applicable to age-hardening and non-age-hardening aluminum and magnesium alloys.

Warm forming of work-hardened sheet alloys

A thermal-assisted method deforms plastically a high-strength material using a high-intensive heat source. The high-strength material may be a cold-rolled sheet aluminum of strength greater than 300 megapascal (MPa) or a cold-rolled sheet steel of strength greater than 1000 MPa. The cold-rolled sheet metal is heated just before bending to a temperature near or above the critical temperature for the material and is followed by rapid quenching after bending.

Thermal-assisted roll forming of high strength material

A composite pressure vessel assembly method includes fitting an end portion of a tubular member into an annular slot formed in an end cap. Sealant may be in the annular slot. The end cap includes an annular groove in an exterior surface of the end cap body portion. A first material layer is formed on an exterior surface of the tubular member. The first material layer includes a first composite material including fibers oriented circumferentially to the tubular member. A second material layer is formed on the first material layer with a portion of the second material layer being disposed into the annular groove, and includes a second composite material including fibers oriented axially to the tubular member. A third material layer is formed adjacent the second material layer and in the annular groove, and includes a third composite material including fibers having an orientation circumferential to the tubular member.

Composite pressure vessel and method of assembling the same

A hemming station is configured for hemming a panel assembly including an outer panel having a hem flange defined by a hem edge. The hemming station includes a roller configured to fold the hem flange, a heating device configured to heat the hem edge, and a control unit. The control unit is configured to control the roller and the heating device such that the roller folds the hem flange when the temperature of the hem edge is in a predetermined temperature range.

Hemmed metal panels, hemming apparatuses, and hemming methods

A method of joining a first and a second work piece, such as automotive closure panels, includes supporting the work pieces on a fixture, and then joining the work pieces to one another by a first solid state weld with a vibrating roller head of a tool assembly, such as a robotically-controlled ultrasonic seam welder. Next, a flange of the second work piece is hemmed about an outer periphery of the first work piece using the same or a different roller head with the work pieces supported by the fixture. The hemmed flange is then joined to the first work piece by a second solid state weld with the vibrating roller head of the robotically-controlled ultrasonic seam welder. A system for joining a first and a second work piece is also provided.

Method of joining by roller hemming and solid state welding and system for same

The present invention provides a method and device for inductively heating a first and second surface to form a closure assembly. A method contemplated by the present invention includes spacing an upper die from a lower die for receipt of the first surface and the second surface configured in an overlying orientation, securing one end of the first surface to an end of the second surface and compressing the first surface toward the second surface to form a compressed arrangement which is inductively heated into a closure assembly.

Induction weld assembly of closure panels

A system for annealing a formable panel includes a stamping press configured to pre-form the panel using a first die and a second die. The system also includes a transfer device configured to engage the pre-formed panel and transfer the panel from the stamping press. The transfer device includes a heating element configured to anneal the pre-formed panel. The heating element anneals the pre-formed panel in the stamping press after the first die is disengaged from the panel and while the panel is being supported by the second die. A method of processing a formable panel and a method of processing a pre-formed panel in a multi-stage stamping operation, each using the system, are also disclosed.

System and method for annealing of a pre-formed panel

The substitution of aluminum alloy roof panels for the low carbon steel roof panels most commonly used in motor vehicles is an attractive option for vehicle mass reduction. Often, however, the remainder of the vehicle body structure continues to be fabricated of steel. The combination of the aluminum alloy roof attached to the steel body may create compressive stresses in the aluminum roof when the body is subjected to elevated temperatures such as those required to cure or bake the paint applied to the body. These stresses may lead to unacceptable appearance features in the visible segment of the roof. By modifying the roof stamping to introduce a tabbed flange for attachment to the body and/or modifying the generally-vertical wall joining the flange to the roof interior, the stresses may be minimized and relocated to segments of the roof not normally visible.

Aluminum roof panel for attachment to supporting steel vehicle body members

An impact beam assembly includes a beam of high-strength steel, and a pair of end brackets constructed of a dissimilar material than the high-strength steel. The brackets are locally deformed onto the beam to thereby surround a portion of the beam. Once deformed, the brackets define a flat section suitable for welding to a vehicle door panel, as well as a section for retaining the beam. The beam can include a surface feature suitable for retaining the beam to the end brackets. A method of reinforcing a vehicle door assembly includes positioning the beam with respect to the end brackets such that the brackets surround a portion of the beam, and then activating a magnetic pulse coil (MPC) to deform an overlapping portion of the brackets onto the beam. The brackets are then attached to a surface of the door assembly to reinforce the door assembly.

Mixed metal magnetic pulse impact beam

An apparatus for hemming multiple panels includes an anvil having a first panel and a second panel supported thereon. A roller mechanism and a curing mechanism are mounted to the hemming apparatus. The roller mechanism is adapted to move relative to the panels to fold a flanged portion of the first panel onto an edge portion of the second panel to form a joint. The curing mechanism is adapted to move relative to the panels to cure an adhesive located within the joint formed between the first panel and the second panel. The curing mechanism is located proximate to the roller mechanism, such that the first panel and the second panel may be supported by the anvil while the curing mechanism at least partially cures the adhesive.

Roller hemming with in-situ adhesive curing

A method of accomplishing precipitation hardening of a selected portion of an aluminum panel is disclosed herein. The method includes identifying at least one area of the aluminum panel that experiences thermal stress above a threshold value during a bake cycle, thereby identifying the selected portion. Prior to the bake cycle, the method further includes locally heating the selected portion at a predetermined temperature for a predetermined time sufficient to increase a local yield strength of the selected portion such that the increased local yield strength ranges from 150 MPa to 300 MPa.

Local heat treatment of aluminum panels

One exemplary embodiment of a high pressure tank and a method thereof includes providing a liner of the high pressure tank. A liner having at least one open end with a first inner diameter and a first outer diameter. The method also including providing a cap having a second outer diameter which is greater than the first inner diameter. The method further includes providing a collar having a second inner diameter which is less than the first outer diameter. The liner is brought to a first temperature, the cap is brought to a second temperature which is less than the first temperature, and the collar is brought to a third temperature which is greater than the first temperature. At least a portion of the cap is placed inside the open end and at least a portion of the collar is placed over the open end.

High pressure tank and method thereof

A method may include providing an outer panel that may have a flange that defines at least one planar section. The flange may be heated at the at least one planar section, and the flange may be bent about the at least one planar section.

Method of making an automotive closure panel assembly

A door assembly for a vehicle includes an outer panel. A support panel is operatively connected to the outer panel and configured such that the support panel provides bending resistance to the outer panel when the outer panel is deflected toward the support panel during a first deflection distance of the outer panel. A cable is operatively connected in the door assembly between a first end and a second end of the outer panel such that the cable provides additional bending resistance to the outer panel when the outer panel is deflected toward the support panel during a second deflection distance of the outer panel, greater than the first deflection distance.

Door assembly and method for a vehicle

An apparatus and method is provided for hemming together a pair of panels and immediately sealing the hemmed joint against the intrusion of moisture. A tool mount is attached to a multi-axis manipulator such as a robot for moving the tool mount along the edge portions of the panels. A hemming roller is mounted on the tool mount and adapted to be moved along the edge portions of the panels by the multi axis manipulator to fold the flanged edge portion of the outer panel onto the edge portion of inner panel as the tool mount traverses the edge portions of the panels. A sealing mechanism is mounted on the tool mount adjacent to the hemming roller to seal the hemmed joint immediately after the flanged edge portion is folded onto the inner panel. The sealing mechanism may be a dispenser of adhesive sealer or a friction stir welder.

Method and apparatus for hemming and sealing a joint

Growing community of inventors

Clinton Township, MI, United States of America

John E Carsley