Dana Corporation

Scott M McGill

Richard A Marando

Andrew R Simboli

Jason A Poirier

Christopher A Rager

Samuel V Martin

A method of manufacturing a node for joining a plurality of structural members together, such as in a vehicular body and frame assembly, is well suited for joining structural members that are formed from differing materials. An insert is provided having a node securing portion and a mounting portion that is adapted to have a structural member secured thereto. A node is formed about the node securing portion of the insert for joining a plurality of structural members together. The insert can be formed from a first material, while the node can be formed from a second material that is different from the first material. The insert can be provided with a node securing portion having at least one aperture or protrusion formed therein, and the node can be formed within or about the aperture or protrusion. A plurality of inserts can be provided, each having a node securing portion and a mounting portion, and the node can be formed about each of the node securing portions of the inserts. The structural members can be secured to the mounting portions of the inserts before the node is formed.

Method of manufacturing a node for connecting vehicle frame members

A method is performed for permanently attaching framing structural members to an underbody of an automotive vehicle. An underbody structural member including one or more cross members and a plurality of metallic structural members are provided at a workstation. The underbody structural member is aligned to the plurality of metallic structural members at the workstation. The assembled underbody structural member and the plurality of metallic structural members are permanently and simultaneously secured at the workstation using magnet pulse welding.

Simultaneous magnetic pulse framing

A method of manufacturing a vehicle frame assembly includes forming a crush box that absorbs energy in a controlled manner during a collision. The crush box is formed by providing first and second members, each including a web portion having first and second flange portions extending therefrom that terminate in respective edges. The first and second members are aligned such that the edges of the flange portions of the first member are aligned with and abut the edges of the flange portions of the second member in a non-overlapping relationship. Then, a butt welding process is performed to secure the flange portions of the first member with the flange portions of the second member. Lastly, the crush box is secured to a portion of the vehicle frame assembly.

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Kenilworth, PA, United States of America

Scott M McGill