Ford Global Technolgoies, LLC

Kiran Kumar Mallela

S George Luckey, Jr

Stephen Kernosky

Andrey M Ilinich

Christopher John May

Brett D Irick

A method is disclosed for forming an aluminum alloy vehicle body component. An aluminum alloy billet is extruded into an aluminum tube that includes longitudinal weld seams formed in a sidewall of the tube during extrusion. A weld seam locating pip is also formed on a sidewall of the tube during extrusion. The pip is used to locate the weld seams during manufacturing of the body component.

Method of forming extruded tubing for vehicle body component

An extruded aluminum alloy tube for hydroforming into an automotive body component includes a wall defining a closed perimeter. The wall includes weld seams disposed in the wall and running longitudinally along the tube. An extruded pip is disposed on the wall and runs longitudinally along the tube. The pip is parallel to the seams and is configured to identify a location of the seams for alignment of the tube during manufacturing.

Aluminum porthole extruded tubing with locating feature

A punch including a shearing edge formed on an outer periphery of the punch, a cutting edge formed on the distal end of the punch and at least two ramp surfaces provided between the shearing and cutting edges. Each of the ramp surfaces extend at an angle from the distal end to a recessed portion of the shearing edge. The shearing edge, cutting edge and ramp surfaces cooperate to partially form a hole in a part and retain a slug in the hole. A method of forming a hole and a slug control system for a hydro-piercing operation is disclosed.

Punch and method for piercing holes with a retention structure

A pressure sequence hydro-forming method is used to form an extruded structural tube. The extruded structural tube is placed in a hydro-forming die that is partially closed to compress the tube. The tube is filled with a hydro-forming liquid at a first pressure. The hydro-forming die is then closed and the pressure of the hydroforming fluid is increased as the hydro-forming die is fully closed. The pressure is increased to a second level of pressure to shape the tube into the desired part shape.

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Ann Arbor, MI, United States of America

Kiran Kumar Mallela