Magna International Inc.

Mark Justin Jones

Edward Karl Steinebach

Jeremiah John Brady

Hongping Gu

Darren Andrew Womack

Jeffrey Jay Mellis

Richard Lee Winfree

Gerard Michael Ludtka

Aldo Anthony Van Gelder

Kenneth Ray Adams

Aldo Van Gelder

Warren Edward Young

Erryn Leigh Ashmore

Venugopal Garimella

Paul James Marston

Edward K Steinebach

Kenneth R Adams

The invention provides a component formed of an aluminum alloy for use in a vehicle, for example an automotive vehicle component requiring high strength, light-weight, and a complex three-dimensional shape, and a method of manufacturing the component. The method begins by providing a blank formed of an aluminum alloy which is already solution heat treated and tempered, and thus has a temper designation of about T4. The method further includes heating the blank to a temperature of 150° C. to 350° C., preferably 190° C. to 225° C. The method next includes quickly transferring the blank to a hot or warm forming apparatus, and stamping the blank to form the complex three-dimensional shape. Immediately after the forming step, the component has a temper designation of about T6, but preferably not greater than T6, and thus is ready for use in the vehicle without any post heat treatment or machining.

High strength aluminum stamping

The present invention relates generally to laser welding in the manufacture of sheet metal components, such as for example automobile components. More particularly, the present invention relates to a process and a system for forming a localized anti-corrosion surface layer along a laser welded joint (weld bead), subsequent to the laser welding together of sheet metal plates having an anti-corrosion surface layer pre-coat.

Method of laser beam localized-coating

A bumper system including a bumper beam being cast from metal having a front panel and a back panel, extending between a first bumper beam end and a second bumper beam end. A plurality of reinforcing ribs integrally cast with the bumper beam extends between the front panel and the back panel defining a non-uniform cross-sectional profile along a portion of the bumper beam. The front panel includes a front center portion disposed between a pair of front side portions. The back panel includes a back center portion disposed between a pair of back side portions. The front center portion has a front center portion thickness greater than a back center portion thickness. Each of the front side portions has a front side portion thickness being less than a back side portion thickness of adjacent one of the back side portions. Method of manufacturing the bumper system is provided.

Cast bumper system and method of manufacturing same

The invention provides a method of manufacturing a component formed of an aluminum alloy for use in an automotive vehicle application, for example those requiring high strength, light-weight, and a complex three-dimensional shape. The method begins by providing a blank formed of an aluminum alloy which is already solution heat treated and tempered, and thus has a temper designation of about T. The method further includes heating the blank to a temperature of 150&#xb0; C. to 350&#xb0; C., preferably 190&#xb0; C. to 225&#xb0; C. The method next includes quickly transferring the blank to a hot or warm forming apparatus, and stamping the blank to form the complex three-dimensional shape. Immediately after the forming step, the component has a temper designation of about T, but preferably not greater than T, and thus is ready for use in the automotive vehicle application without any post heat treatment or machining.

A process is described for laser welding a sheet metal workpiece having an anti-corrosion pre-coat on at least one major surface thereof and having first and second opposite side edges. The sheet metal workpiece is arranged such that the first and second side edges are in contact with one another and such that the at least one major surface faces outwardly. A laser beam having a first beam spot-size, is used to form a laser weld joint between the first and second side edges. Subsequently, a localized anti-corrosion surface layer is formed on the laser weld joint. To this end, a laser beam having a second beam spot-size larger than the first beam spot-size is scanned along the laser weld joint. During the scanning, a flow of a powdered anti-corrosion surface layer material is directed toward a portion of the laser weld joint that is being irradiated by the laser beam. The laser beam melts the material, which subsequently solidifies to form a layer adhering to the laser weld joint.

A vehicle bumper assembly includes a bumper beam and a crash box. At least one of the bumper beam or the crash box is cast from metal, such as aluminum or magnesium, to reduce weight, reduce manufacturing process steps, and improve performance characteristics of the bumper assembly. In an embodiment, both of the bumper beam and the crash box are cast from metal to establish an integral connection therebetween. One of the bumper beam or the crash box can be open along a top and bottom portion of the bumper assembly and include at least one reinforcing rib cast integral therewith. In an embodiment, both of the bumper beam and the crash box can be open along a top and bottom portion of the bumper assembly and each include at least one reinforcing rib cast integral therewith.

Cast bumper assembly and method of manufacturing same

A process is disclosed for laser-welding sheet metal plates that have an aluminum-silicon containing pre-coat layer. The pre-coated sheet metal plates are arranged one relative to another such that an edge of one of the plates is adjacent to and in contact with an edge of the other one of the plates, and a laser-welded joint is formed along the adjacent edges of the pre-coated plates. In particular the joint is formed absent removing the aluminum-silicon containing layer from along the adjacent edges, such that aluminum from the aluminum-silicon containing layer enters into the melt pool that is formed. Additionally, an alloying material is introduced into the melt pool during forming the laser-welded joint and forms a compound with at least some of the aluminum in the melt pool.

Method of laser welding coated steel sheets with addition of alloying elements

A process is described for laser welding a sheet metal workpiece having an aluminum-silicon containing pre-coat layer disposed on at least one major surface thereof, and having first and second opposite side edges. The sheet metal workpiece is arranged such that the first and second side edges are in contact with one another and such that the at least one major surface faces outwardly. A closed tube-shaped product is obtained by forming a laser-weld joint between the first and second side edges. In particular the laser-weld joint is formed absent removing the aluminum-silicon containing layer from along the adjacent edges, such that aluminum from the aluminum-silicon containing layer enters into the melt pool that is formed. An alloying material is introduced into the melt pool during laser welding and forms a compound with at least some of the aluminum in the melt pool.

Growing community of inventors

Knoxville, TN, United States of America

Mark Justin Jones