Gm Global Technolgoy Operations, Inc.

Stephen R Koshorek

Adrian B Chernoff

Richard Murray Kleber

Michael D Hanna

John Neal Owens

John E Carsley

Chih-Cheng Hsu

Chongmin Kim

Albert H Butlin, Jr

Mark G Konopnicki

Jacob Lyjak

Hui-Min Huang

A door assembly for a vehicle includes an outer panel. A support panel is operatively connected to the outer panel and configured such that the support panel provides bending resistance to the outer panel when the outer panel is deflected toward the support panel during a first deflection distance of the outer panel. A cable is operatively connected in the door assembly between a first end and a second end of the outer panel such that the cable provides additional bending resistance to the outer panel when the outer panel is deflected toward the support panel during a second deflection distance of the outer panel, greater than the first deflection distance.

Door assembly and method for a vehicle

A method for manufacturing a lower body component for a vehicle is provided including forming a one-piece floor pan at least partially defining a vehicle passenger compartment and substantially extending longitudinally at least the entire length thereof, and forming a one piece reinforcement structural member for reinforcing the pan. The method also includes simultaneously forming the pan and one-piece reinforcement structural member by stacking a pair of weldable sheet metal blanks sufficiently close together to define a comon interface, positioning the stacked blanks between moveable profile forming dies, heating the dies so that the blanks reach a superplastic forming temperature, and plastically deforming the stacked blanks into a lower body component having the profile of the dies. The method also includes friction stir welding of the stacked blanks at the common interface.

Automotive lower body component method of manufacture

Small sheet metal reinforcement pieces are co-formed with a larger sheet metal part during a hot stretch forming against a heated forming tool surface. Locator holes are made in blanks for the reinforcing pieces so they can be precisely located on locator pins in the forming surface where the reinforcing pieces are ultimately to be attached to the formed sheet part. A preheated blank of the larger part is stretched against the trapped reinforcement blanks and both the part and reinforcing pieces are shaped against the hot tool. The part and reinforcing pieces are removed and cooled, and the closely fitting reinforcing pieces attached to the part at a suitable later time.

Making panel reinforcements during hot stretch forming

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Royal Oak, MI, United States of America

Stephen R Koshorek