Gm Global Technolgoy Operations, Inc.

Other

3m Innovative Properties Company

Joseph M Lendway, Iv

Charles J Bruggemann

Sanjay Mahasukhlal Shah

Chi-Mou Ni

Kent S Tarbutton

Alexander D Khakhalev

David A Gatny

Pei-chung Wang

Bradley J Blaski

Spyros Pete Mellas

Peter M Parlow

John D Fickes

Daniel C Hutchinson

Mark T Hall

Mark D Gugel

Michael Gerard Poss

Athreya Nagesh

Mark Goebel

Tuan A Ngo

Carl W Robinson

Jason Ohls

Gregory J Zywicki

William Henry Todd, Jr

Don Reams

Paul A Benton

In an accordance with an exemplary embodiment, an energy director is provided for use in ultrasonic welding, the energy director including: a first raised region extending upward from a surface of a base of a component to be welded; and a second raised region extending upward from the first raised region; wherein the first raised region is disposed underneath the second raised region, such that when material of the second raised region melts, the material of the first raised region is not melted and maintains an adhesive bond line thickness.

Energy director design

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 tool peels apart a sample weld between a top sheet and a bottom sheet of metal while the bottom sheet is held in a vise. The tool includes a wheel having a peripheral rim surface. A handle is attached to the wheel so that rotating the handle rotates the wheel. A clamping mechanism is mounted on the wheel and moves between an open position spaced from the peripheral rim surface and a closed position in which the clamping mechanism clamps the top sheet to the peripheral rim surface so that rotation of the wheel by the handle will progressively wrap the top sheet about the peripheral rim of the wheel and thereby forcibly peel the top sheet away from the bottom sheet to pull apart the weld between the top and bottom sheets.

Tool for peeling apart a weld sample

A tool is provided for forming a dimple on the edge of a metal sheet to facilitate projection welding of the sheet to an adjacent metal sheet. A reversible drill motor has a housing and chuck. A mounting bracket clamps onto the housing and a base is attached to the mounting bracket. A frame is attached to the base and has spaced apart arms. A first dimple forming die is mounted on one of the arms and a second dimple forming die is slidably mounted on the other of the arms. A driveshaft has a threaded end engaged in a threaded aperture of the second dimple forming die and a drive end captured in the chuck. Rotation of the driveshaft in one direction advances the second dimple forming die toward the first dimple forming to form a dimple in a sheet edge interposed between the dies.

Dimple-forming tool for projection welding

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 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 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 hydroformable frame element is formed from the combination of at least two elements. The at least two elements are designed with a partially overlapping region, with an annular space defined within the overlapping region. The annular space is filled with adhesive, which is then cured to bond the at least two elements together. The adhesive bond is designed to withstand the stresses caused by the hydroforming operation and to retain its strength so that the hydroformed article is then usable as a vehicular frame element.

Method of hydroforming articles and the articles formed thereby

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 method for hydroforming a large surface area, double paneled, hollow auto body part, such as a hood, in which the inner and outer panels are concurrently shape formed and seamed structurally together in the same apparatus. A pair of upper and lower dies crush the edges of a double walled blank together between the dies so as to simultaneously clamp, seal, and form the seam. Then, a special face seal and fluid inlet assembly grips and holds the edges of an inlet hole near the center of the blank to allow the interior to be successfully pressurized and expanded.

Method for hydroforming a hollow sheet metal body part

An apparatus allows a robot arm located in from of a body panel to create a spot weld joint located inboard of and behind an edge of the panel. A bracket fixed to the wrist of the robot arm has an open side wide and deep enough to reach around and behind the panel edge, so that an electrode fixed to the bracket can be aligned with the desired weld location. Then, a power cylinder pulls the bracket inward until the electrode hits the weld point, under tension. The electrode then fires to create the joint, and is retracted and moved. The robot arm and wrist remain entirely in front of the panel, and no access holes in the panel are needed to reach the remote weld point.

Growing community of inventors

Dryden, MI, United States of America

Joseph M Lendway, Iv