Magna International Inc.

Cosma Engineering Europe Ag

Cosma International Inc.

Seetarama S Kotagiri

Frank A Horton

Alexander Zak

Timothy Walter Skszek

Gregory Paul Kiselis

Gianfranco Gabbianelli

Mark Francis Werner

Jeffrey Jay Mellis

Warren Edward Young

Dalip K Matharoo

Ying Zhang

DeWayne Dale Egle

Daniel Sulisz

Boris Shulkin

Andreas Stranz

Ryan Robert Warpup

Pascal P Charest

Eric deNijs

Erryn Leigh Langlois

Philipp Stoeger

Jim Metz

James Byrne, Ii

Monty Lynn Hansen

Bradford L Hastilow

P Gregory Kiselis

Andreas G Janssen

James R Judkins

Monty Hansen

Gregory P Kiselis

Richard Ashley

Frank Gabbianelli

Erryn Leigh Ashmore

Gary Banasiak

Nikhil Madan Yardi

Mark F Werner

James R Byrne

Dewayne D Egle

Gregory Kiselis

James R Byrne Ii

An explosion forming apparatus () that preferably utilizes a shock wave () directed along a work piece () to progressively conform the work piece to a contour die cavity ().

Explosion forming system

The invention is intended to improve a method for explosive forming of a workpiece by means of gas explosion, in which the workpiece is arranged in a intake area of a moulding tool, wherein the intake area is at least partially filled with liquid and the explosion is triggered by ignition of an explosive gas mixture, to the effect that the method is suitable and simplified for mass production. This object is solved by a method for explosive forming of a workpiece by means of gas explosion, in which the workpiece is arranged in a intake area of a moulding tool, wherein the intake area is at least partially filled with liquid and the explosion is triggered by means of ignition of an explosive gas mixture, in which the explosive gas mixture is provided at least partially above the surface of the liquid before the ignition.

Method and mould arrangement for explosion forming

An automotive component including a composite casting is provided. The composite casting includes a steel member and an end cap fastened to an end portion of the steel member. A cast coupling member is cast about the end portion of the steel member including the end cap, thereby positively and rigidly securing the cast coupling member to the steel member. The automotive component can comprise an engine cradle, a control arm, an instrument panel support structure, a bumper assembly, or a twist axle. The cast coupling member is typically formed by casting-in-place aluminum about the end cap and the end portion of the steel member. The steel member is typically a tubular member, and the end cap typically includes a flange designed to provide a mechanical interlock surface with the cast coupling member. For example, the flange can have a polygonal shape, an outwardly extending member, or notches.

Controlled pressure casting

In one aspect, the invention is directed to a crush can for a vehicle frame including a crush can body having a longitudinal axis and a cross-sectional shape that is at least approximately a 10-sided polygon. In another aspect, the invention is directed to a crush can for a vehicle frame including a crush can body having a longitudinal axis and a cross-sectional shape that includes a plurality of outwardly pointing apexes and a plurality of inwardly pointing apexes.

Scalable crush can for vehicle

A hybrid torsion beam axle assembly is provided, which includes a steel torsion beam. An end cap is fastened to an end portion of the steel torsion beam, and a cast trailing arm is cast about the end portion of the steel torsion beam including the end cap. In this way, the cast trailing arm is positively and rigidly secured to the steel torsion beam.

Hybrid component

A method of forming metal castings, including positioning a first end of a structural member in a first mold cavity and a second end of the structural member in a second mold cavity. The first and second mold cavities being fluidly coupled to a reservoir of molten metal. Applying a main pressure to the molten metal in the reservoir to force the molten metal into the first mold cavity and the second mold cavity. Then, applying a first auxiliary pressure to the first mold cavity and a second auxiliary pressure to the second mold cavity to densify the casting formed in the first mold cavity and the second mold cavity. Also, a method for casting including maintaining a main pressure at or less than an initial, mold-filling pressure after first and second mold cavities have been filled. Additionally, a method for detecting whether a first mold cavity is sufficiently filled with molten metal by monitoring a moveable element.

The invention is intended to improve a tool arrangement and method for explosive forming of a workpiece by means of gas explosion, in which the workpiece is arranged in a intake area of a molding tool, wherein the intake area is at least partially filled with liquid and the explosion is triggered by means of ignition of an explosive gas mixture, to the effect that the tool arrangement and the method are suitable and simplified for mass production. This object is solved by means of a tool arrangement and a method for explosive forming of a workpiece by means of gas explosion, in which the workpiece is arranged in a intake area of a molding tool, wherein the intake area is at least partially filled with liquid and the explosion is triggered by means of ignition of an explosive gas mixture, in which the explosive gas mixture is provided at least partially above the surface of the liquid before the ignition.

A hot forming die that includes a first die and a second die. The first die has a first die structure that is formed of a tool steel. The first die structure has a first die surface and a plurality of first cooling apertures. The first die surface has a complex shape. The first cooling apertures are spaced apart from the die surface by a first predetermined distance. The second die has a second die surface. The first and second die surfaces cooperate to form a die cavity. Related methods for forming a hot forming die and for hot forming a workpiece are also provided.

Hot stamping die apparatus

In one aspect, the invention is directed to a twist beam axle for a vehicle. The twist beam axle includes a twist beam and a reinforcement member. The twist beam has a longitudinal axis and has a generally concave cross-sectional shape. The reinforcement member extends longitudinally and is connected to the twist beam to form a longitudinally extending tubular form therewith. The twist beam has first and second side walls. At least one of the side walls extends outside of the tubular form. The tubular form has cross-sectional dimensions that are selected based on the vehicle on which the twist beam axle is to be used.

Torsion beam of twist axle

A hybrid component for lightweight, structural uses, including a steel member formed of a high strength steel; and a cast coupling member cast on a portion of the steel member by casting-in-place a semi-solid aluminum about the portion of the steel member, thereby positively and rigidly securing the coupling member to the steel member. A method of forming a hybrid component for lightweight, structural uses, including: forming a steel member formed of a high strength steel into a predetermined configuration; and casting a coupling member on a portion of the steel member by casting-in-place a semi-solid aluminum about the portion of the steel member, thereby positively and rigidly securing the coupling member to the steel member.

A method of forming metal castings includes positioning a first end of a structural member in a first mold cavity and a second end of the structural member in a second mold cavity. The first and second mold cavities are fluidly coupled to a reservoir of molten metal. A main pressure is applied to the molten metal in the reservoir to force the molten metal into the first and second mold cavities. First and second auxiliary pressures are applied to the first and second mold cavities to densify the castings formed in the first and second mold cavities. Another method for casting includes maintaining a main pressure at or less than an initial, mold-filling pressure after the first and second mold cavities have been filled. Additionally, a method for detecting whether a first mold cavity is sufficiently filled with molten metal includes monitoring a moveable element.

A motor vehicle frame includes a pair of longitudinal frame members. A cross member is provided to maintain the frame members in a spaced apart condition. The cross member has a first end configured to mount to a first one of the longitudinal frame members and a second end configured to engage a steering gear housing. The second end sandwiches steering gear housing as the second end is fastened to a second one of the frame members.

Integral cross member with steering gear joint

Growing community of inventors

Rochester Hills, MI, United States of America

Seetarama S Kotagiri