Gm Global Technolgoy Operations, Inc.

Other

Jon T Carter

Anil Kumar Sachdev

Paul Edward Krajewski

Leonid Charles Lev

Blair E Carlson

Ravi Verma

David R Sigler

Robert N Saje

Elisabeth Jane Berger

Tyson W Brown

Yang T Cheng

Guangling Song

Raja K Mishra

Matthew Simonin

Peter H Foss

Asim Tewari

Deepika Sachdeva

Joshua D Lasceski

Carolina C Ang

James Gregory Schroth

Arun Kumar

Thomas Arthur Perry

Bin Hu

Michael D Hanna

Jianfeng Wang

Bob Ross Powell

Pulak Bandyopadhyay

Inwook Hwang

Kiran Deshpande

Shashank Tiwari

Sushil Kumar Mishra

Daniel George Valik

Jongcheol Shin

Jongwon B Park

A panel assembly is formed by a plurality of bonds between two sheet materials in a face to face relationship to form a preform. The plurality of bonds define a closed perimeter region between the two sheet materials and an open perimeter region between the two sheet materials. The preform may be formed into a predefined shape. Pressurized fluid is applied through an inlet into the open perimeter region to expand the preform. The pressurized fluid expands the open perimeter region such that the two sheet materials expand in an opposing direction, thereby defining an expanded open perimeter region. The closed perimeter region between the two sheet materials remains vacant of the pressurized fluid such that the closed perimeter region is not expanded. The expanded open perimeter region is filled with a filler material for improving a performance characteristic of the panel assembly, e.g., strength, sound absorption, or stiffness.

Tailored panel assembly and method of manufacturing the same

Methods for casting high strength, high ductility lightweight metal components are provided. The casting may be die-casting. A molten lightweight metal alloy is introduced into a cavity of a mold. The molten lightweight metal alloy is solidified and then a solid component is removed from the mold. The solid component is designed to have a thin wall. For example, the solid component has at least one dimension of less than or equal to about 2 mm. In this way, a chill zone microstructure is formed that extends across the at least one dimension of the solid lightweight metal alloy component. The solid component thus may be substantially free of dendritic microstructure formation, enabling more extensive alloy chemistries than previously possible during casting. Such methods may be used to form high strength, high ductility, and lightweight metal alloy vehicle components.

Chilled-zone microstructures for cast parts made with lightweight metal alloys

A method of forming an article from a metal alloy sheet material includes selectively hardening only a first localized area of the metal alloy sheet material without hardening a second localized area of the metal alloy sheet material, wherein the second area adjoins the first area to thereby form a blank. The blank has a hardened region formed from the first area and having a first hardness, and a non-hardened region adjoining the hardened region and formed from the second area, and having a second hardness that is less than the first hardness. The method includes stamping the blank to thereby form a preform having a pre-protrusion at least partially formed from the hardened region, wherein the pre-protrusion has a first height, annealing the preform to thereby form a workpiece, and stamping the workpiece to increase the first height and thereby form the article.

Method of forming a stamped article

A first layer is established on a second layer and an induction coil is disposed within induction proximity to the second layer. The induction coil is electrically energized thereby heating the second layer to a target temperature. A die having a die cavity is translated from a first location spaced substantially beyond an induction heating distance from the induction coil to a clamping location adjacent the second layer such that the induction coil surrounds a predetermined location on an external surface of the die. The die is heated by induction between the induction coil and the die while the die is translated toward the clamping location until the die reaches a predetermined die temperature. The induction coil is de-energized after the die has reached the predetermined die temperature. The first layer and the second layer are clamped between a binder and the die.

Clinching method and tool for performing the same

The corrosion resistance of formed and shaped sheet magnesium alloy articles may be improved by applying to the article a substantially crack- and pore-free ductile metal layer on at least selected surfaces and cut or sheared edges. An exemplary ductile metal may be aluminum or its alloys. Two methods of applying such a ductile metal layer are described. One method is suitable for extended areas of the magnesium alloy surface, and is applied prior to stamping the article while a second method, suitable for cut or sheared edges, is intended for application after the article is fully formed. The incorporation of both embodiments into conventional sheet metal stamping processes to form the corrosion resistant formed magnesium article is described.

Corrosion resistant magnesium article method of making

A method of forming an article from a metal alloy sheet material includes stamping the metal alloy sheet material to thereby form a preform having at least one protrusion. The at least one protrusion includes a base portion, a first region having a first thickness and spaced apart from the base portion to thereby have a first maximum height, and a second region interconnecting the base portion and the first region and having a second thickness that is greater than the first thickness. After stamping, the method includes selectively annealing the second region without substantially annealing the first region, and, after selectively annealing, concurrently increasing the first maximum height and substantially equalizing the first thickness and the second thickness to thereby form the article.

Method of forming an article from metal alloy sheet material

Methods of joining a magnesium substrate to a second substrate are provided. A region of the magnesium substrate and a region of the second substrate are aligned to provide an overlap. A region of the overlap is deformed to provide a joint. A polymeric material is disposed in the joint to secure together the magnesium substrate and the second substrate. The joining of the magnesium substrate and the second substrate is facilitated by using a die in various aspects.

Method of joining magnesium

A magnesium alloy panel for a vehicle includes a first region and a second region extending from the first region to an edge. The first region has a first microstructure having a first corrosion resistance. The second region has a second microstructure different than the first microstructure and has a second corrosion resistance greater than the first corrosion resistance. A system for mass producing magnesium alloy panels includes a forming apparatus and a laser cutting apparatus. The forming apparatus forms a panel having a first microstructure having a first corrosion resistance. The laser cutting apparatus cuts the panel to form the edge using a laser, and forms the second microstructure while forming the edge. The second microstructure is different than the first microstructure and has a second corrosion resistance greater than the first corrosion resistance. A method for mass producing magnesium alloy panels is also provided.

System and method for manufacturing magnesium body panels with improved corrosion resistance

A method for stamping a desired shape from a sheet blank includes providing the sheet blank. The method also includes locally cooling the sheet blank with a stream of fluid in a predetermined area of high stress concentration to be experienced during forming of the sheet blank into a desired shape. The method additionally includes forming the metal sheet blank into the desired shape in a stamping press with a punch. A system employing the method for forming a sheet blank is also disclosed.

Fluid-assisted non-isothermal stamping of a sheet blank

A replaceable deformable insert is disposed in a clinching die cavity having an annular recess adjacent the insert. A first layer is established on a second layer and secured between a retractable punch and the clinching die. The punch is pressed into the first layer to form a depression in the first and second layers. The first and second layers are compressed together between the punch and the clinching die, creating hydrostatic pressure in the first and second layers and the insert. A portion of the insert is extruded to fill the annular recess with insert extrudate, while a portion of the second layer is simultaneously radially extruded into an annular space previously occupied by the insert. A portion of the first layer is simultaneously radially extruded into an annular volume previously occupied by the second layer, thereby forming an interlocking assembly of the first and second layers and insert.

A double-action clinching tool includes a support having an aperture formed therein and a surface configured to receive a first layer overlapping a second layer. A clinching punch is slidably positioned in the support aperture and configured to engage the second layer. A punch is positioned opposite to the clinching punch and is configured to form an aperture in the first layer prior to the clinching punch engaging the second layer. A retractable clinching die configured to contact the first layer and to shift such that an interior wall thereof is angularly offset from an initial position when contacted by a portion of the second layer extending through the aperture of the first layer.

Double-action clinching tool

A method of manufacturing a closure assembly for a vehicle includes trimming an outer panel to define a first edge and trimming an inner panel to define a second edge, wherein the outer panel is formed from an aluminum alloy material and the inner panel is formed from a magnesium alloy material. The method further includes chemically shaping the second edge to define a substantially rounded edge surface having a radius, positioning the inner panel adjacent the outer panel such that the first edge extends beyond the substantially rounded edge surface, and bending the first edge of the outer panel around the substantially rounded edge surface of the inner panel to form a hem connection that secures the inner panel relative to the outer panel. A closure assembly is also disclosed.

Closure assembly and method of manufacturing same

A method of enhancing the ductility of magnesium alloy sheets containing 85% or more by weight of magnesium is described. An annealed, substantially strain free, sheet of generally uniform grain size is locally deformed in local regions to develop strained 'islands' of a predetermined strain embedded in a substantially strain-free matrix and then annealed. The deformed regions undergo recrystallization and grain growth while the remainder of the sheet suffers only minor change in grain size, leading to sheet with grains having a bimodal size distribution. The ductility of alloys processed in this way is significantly greater than the ductility of the unprocessed, uniform grain size alloy without compromise to the tensile strength of the alloy.

Making ductility-enhanced magnesium alloy sheet materials

A system may be used to detect corrosion between a first metal and a second metal, where the second metal is positioned adjacent to the first metal. The system may include a processor electrically coupled to each of the first and the second metals and configured to monitor a complex impedance between the first metal and the second metal, where the complex impedance may include a real component and an imaginary component. The processor may compare the real component of the complex impedance to a first threshold, compare the imaginary component of the complex impedance to a second threshold, and indicate a likelihood of corrosion if at least one of the real and imaginary components are below their respective threshold.

Growing community of inventors

Farmington, MI, United States of America

Jon T Carter