Gm Global Technolgoy Operations, Inc.

Sooho Kim

Ravi Verma

Paul Edward Krajewski

Chongmin Kim

Moinuddin S Rashid

Frederick Irvin Saunders

Anil Kumar Sachdev

Richard Murray Kleber

Chih-Cheng Hsu

Mark A Voss

Raja K Mishra

Edward Frank Ryntz

Edward F Ryntz, Jr

Gary R Pelowski

George L Kilbertus

Curtis L Shinabarker

Kulsum Rashid, Legal Representative

David W Poma

Nicholas M Bosway

A billet of an aluminum alloy or magnesium alloy is formed by a combination of forming operations into a desired article of complex, but open shape. In a first step a billet is heated and extruded to form an extruded workpiece profile having at least first and second sections of different thicknesses. The extruded workpiece may be shaped so that the respective sections are at an angle to each other. The extruded workpiece is then further formed against a forming surface so that the shape of least one of the sections is further formed toward the shape of the article. The methods are suitable for efficient manufacture of many like complex shapes such as brackets and reinforcement members, and even container pans for computers and other electronic devices.

Forming of complex shapes in aluminum and magnesium alloy workpieces

One embodiment includes a lightweight automotive vehicle door construction including an inner panel partially formed from a lightweight metal casting. The casting provides a toe pan, hinge pillar and beltline. A lightweight stamping connected with the casting provides a remainder of the inner skin. The stamping provides an opposite pillar and latch mount. A header connected to the casting along a first end and with the beltline at a second end provides a window frame. A side intrusion beam extends between the hinge pillar and the opposite pillar. An outer panel is connected with the inner panel.

Automotive vehicle door construction

A method is disclosed for stretching magnesium-containing aluminum alloy sheet stock into intricate shapes such as are required in automotive body panels. The sheet stock, at a temperature in the range of about 400&#xb0; C. to about 510&#xb0; C., is stretched under the pressure of a working gas into conformance with the surface of a forming tool. The sheet forming pressure is increased continually in a controlled manner from ambient pressure to a final forming level in the range of about 250 psi to about 500 psi or higher. A portion of the sheet can experience strain rates substantially higher than 10secand the forming of the sheet can be completed within 12 minutes.

Quick plastic forming of aluminum alloy sheet metal

A magnesium, manganese and copper-containing aluminum alloy sheet material suitable for use in high elongation forming processes is produced according to an improved thermomechanical process. The sheet material is produced by continuous casting with an as-cast gage of 5 to 35 millimeters and immediately hot rolling with a final strip exit temperature between 200&#xb0; C. and 350&#xb0; C. and then coiling. The hot rolled coil is annealed at 450&#x2013;560&#xb0; C. to homogenize the microstructure. After cooling to ambient temperature, the coil is cold rolled to desired sheet thickness with a net gage reduction of 50&#x2013;90 %. After suitable recrystallization of the cold worked microstructure the sheet is ready for hot, high elongation forming.

Continuously cast magnesium containing, aluminum alloy sheet with copper addition

A portable panel position detector for determining the orientation of panels being serially moved on a transfer line into a downstream panel treatment facility comprising a pair of support towers laterally spaced to allow the passage of line supported panels therethrough. The spaced support towers operatively mount elongated and vertically extending sensor strips in opposing spaced relationship that defines clearance-determining gating between the towers. In the event a panel moving through the restricted gate is not properly orientated on the transfer line, at least one sensor strip or a portion thereof will be deflected by physical contact with the panel moving therethrough. The displaced strip effects the triggering of an alarm that advises a transfer line attendant that the panel is improperly loaded. The panel can be appropriately repositioned on the transfer line so that it can successfully pass through the treatment facility without damage.

Portable panel position detector

A method is disclosed for stretching magnesium-containing aluminum alloy sheet stock into intricate shapes such as are required in automotive body panels. The sheet stock, at a temperature in the range of about 400&deg; C. to about 510&deg; C., is stretched under the pressure of a working gas into conformance with the surface of a forming tool. The sheet forming pressure is increased continually in a controlled manner from ambient pressure to a final forming level in the range of about 250 psi to about 500 psi or higher. A portion of the sheet can experience strain rates substantially higher than 10,sec,and the forming of the sheet can be completed within 12 minutes.

Growing community of inventors

Troy, MI, United States of America

Sooho Kim