A method of preparing aluminum metal pieces for welding, along with welded sheet metal assemblies formed from the prepared aluminum metal pieces. In one embodiment, a scanning beam of a laser is directed at an edge portion of the sheet metal piece such that a portion of the scanning beam is configured to impact an oxide layer at the edge portion. The laser is pulsed in a series of ablating pulses at the edge portion, with the ablating pulses creating an ablation plume that includes ablated material from the oxide layer of the primary surface and the peripheral surface of the edge portion. The ablation plume is analyzed, and ablation and analyzing continues until a threshold of at least one constituent in the ablation plume or the analysis plume is met or exceeded. One or more operating parameters of the laser are adjusted based on the analysis of the ablation plume or analysis plume. In some embodiments, two aluminum metal pieces are simultaneously prepared.
A cooling system (12) for a molding tool (10) or molding machine includes a high-performance coolant (14), multiple cooling circuits (36, 136) with different coolants (14, 114) flowing along each circuit, and/or a self-contained cooling circuit (36). The high-performance coolant (14) can include a metallic component in various forms, including a liquid phase metal form. Newly recognized coolant characteristics such as volumetric heat capacity (Cv) can be used to identify suitable coolants. High-performance coolants (14) can be used to reduce molding process cycle times, to spatially equalize the cooling rate of the molding material among different sections of the mold cavity (24), and/or to help cool other parts of the tool (10) or machine such as a runner (32) or an injection sleeve (30).
A vehicle suspension component (16), such as a lower control arm, that includes first and second stamped metal shells (30, 32) and several connection nodes (36, 38, 40) for operably connecting the suspension component to the rest of the vehicle suspension system. The first and second stamped metal shells may be stamped from next generation steel that is lightweight and strong, and are joined together in a clam shell or box-style type design. Each of the connection nodes includes a fixed attachment end (92, 192) and a movable attachment end (94, 194), wherein the fixed attachment end may be sandwiched between the shell connection node portions of the first and second stamped metal shells and welded thereto, whereas the movable attachment end movably or pivotably attaches the vehicle suspension component to the vehicle suspension system.
A vehicle suspension component (16), such as a lower control arm, that includes first and second stamped metal shells (30, 32), a stiffening feature (34), and several connection nodes (36, 38, 40) for operably connecting the suspension component to the rest of the vehicle suspension system. The first and second stamped metal shells may be stamped from next generation steel that is lightweight and strong, and are joined together in a clam shell or box-style type design so that the connections nodes are sandwiched therebetween. The stiffening feature may include a depression (68), a depression perimeter (60) that at least partially surrounds the depression, a depression sidewall (62), a depression floor (64), and a depression weld (66), wherein the depression weld joins the shell interior surfaces of the first and second stamped metal shells together.
Welded parts and methods of manufacturing the same are disclosed. A welded part may include first and second metal workpieces (202, 204) having respective first and second edges forming a butt joint. The welded part may further include a first laser weld (208a) joining the first and second edges on one side of the first and second metal workpieces, and a second laser weld (208b) joining the first and second edges on another opposite side of the first and second metal workpieces. Some example parts may have laser welds that cooperate to extend across an entire depth of the butt joint and form an overlap zone (212) between the first and second laser welds. In some examples, the first and second laser welds may be formed with substantially zero macroporosity.
Composite parts (10), methods of making the same (400), and tooling systems (200) for making the same are disclosed. According to one example, a high-pressure die casting process is used to manufacture a composite part (10) that is made from a composite metal material (12) with a metal matrix phase (20) and a particle phase (22) and includes an interior region (14) and an exterior region (16), where an average concentration of the particle phase (22) in the composite metal material (12) is higher in the exterior region (16) than in the interior region (14). An interior surface (206a, 206b) of a die mold (206) may be coated with a particle phase (22) (e.g., a ceramic-based material) and a molten metal matrix phase (20) (e.g., an aluminum -based material) may then be introduced into the die mold (206) such that a composite part (10) is formed with an exterior region (16) or outer layer that is particle-rich compared to an interior region (14).
B22D 19/08 - Casting in, on, or around, objects which form part of the product for building up linings or coverings, e.g. of anti-frictional metal
B22D 17/20 - AccessoriesPressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure Details
Composite parts (100) and methods of making the same are disclosed. A composite part may include an internal insert component (124) made of a first material. The internal insert component may be provided with surface features such as mechanical surface features or material surface features, on at least a portion of its surface. The composite part may further include an external part component (136) that is cast around at least a portion of the internal insert component, and is made of a second material different from the first material. The surface features of the internal insert component may help establish a bond within the composite part between the internal insert component and the external part component.
B22D 19/16 - Casting in, on, or around, objects which form part of the product for making compound objects cast of two or more different metals, e.g. for making rolls for rolling mills
B22D 19/04 - Casting in, on, or around, objects which form part of the product for joining parts
B22D 17/00 - Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
8.
COMPOSITE PART WITH EXTERNAL PART CAST AROUND INTERNAL INSERT AND METHOD FOR PRODUCING THE SAME
Composite parts and methods for making the same are disclosed. A composite part may include an internal insert component that is coated on at least a portion of its surface with certain types of particles, an external part component cast around the coated insert, and a particle-rich region that is formed between the two components, where the particle-rich region includes particles from the coated insert. A method for producing a composite part may include the steps of: positioning an internal insert component that is coated on at least a portion of its surface within a mold cavity of a casting die; casting a molten material of the external part component around the coated insert; and solidifying the molten material to form the external part component of the composite part.
A hybrid weld joint for joining sheet metal pieces together. According to one example, the hybrid weld joint exhibits characteristics of both butt welds and lap joints and is used to create a tailor- welded blank assembly where at least one sheet metal piece is made of aluminum or an aluminum-based alloy. Such a tailor-welded blank assembly is particularly suitable for the automotive industry.
40 - Treatment of materials; recycling, air and water treatment,
42 - Scientific, technological and industrial services, research and design
Goods & Services
Custom manufacture of structural and reinforcement parts, panels and composites for use in automotive applications and in the commercial truck, appliance and construction industries; and metal laminating Consulting services in the field of design and development of engineering processes; engineering services in the field of reduced weight metal products and components for the automotive, commercial truck, appliance and construction industries
11.
VACUUM-BASED WELD FIXTURE AND METHOD OF USING THE SAME
A vacuum-based weld fixture (100) includes a first work piece support (102) for supporting a first work piece (202) and a second work piece support (104) for supporting a second work piece (204). The first work piece support may be slidable with respect to the second work piece support, and configured to supply a vacuum to the first work piece via at least one opening (110) formed in a work piece support surface (103). The weld fixture includes a gage bar (114) for aligning the first and second work pieces. Reduced pressure created by a vacuum source (300) may be communicated to the opening in the work piece support surface, thereby holding the first work piece in place while the first work piece is aligned against the gage bar prior to welding.
B23K 37/04 - Auxiliary devices or processes, not specially adapted for a procedure covered by only one of the other main groups of this subclass for holding or positioning work
B23K 31/02 - Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by any single one of main groups relating to soldering or welding
B23Q 3/08 - Work-clamping means other than mechanically-actuated
A shaping tool (10, 110) includes a cooling system (12) having one or more cooling passages (26, 126) configured for enhanced cooling. The cooling passages provide latent heat cooling of a heated material that is in contact with a shaping surface (24, 124) of the tool. Cooling fluid flows along the cooling passages in a two-phase flow regime in which a portion of the cooling fluid is liquid and a portion of the cooling fluid is vapor. A two-phase portion (28, 128) of the cooling passage can be shaped to follow a three-dimensional contour of the shaping surface. Opposing walls of the cooling passage can be provided by passage surfaces (42, 44, 142, 144) of separately formed pieces of the tool. The latent heat cooling provided by suitably configured cooling channels extracts more heat from the material being shaped in the tool than traditional cooling systems.
A steering knuckle assembly that is made of a lightweight material, such as an aluminum-based material, but is strong enough to withstand various induced stresses like those caused during a press-fit installation of a wheel bearing assembly. In one embodiment, the steering knuckle assembly includes a steering knuckle component made of an aluminum-based material that is over-molded or cast around a reinforcing insert made of a stronger ferrous-based material. The reinforcing insert has an inner surface surrounding an opening that is designed to receive a wheel bearing assembly, where the inner surface can be machined before or after the over-molding or casting process.
A panel assembly 10 that includes a main panel 12, a sound-damping patch 14, a sound-damping adhesive layer 16, and a structural adhesive joint 18. The structural adhesive joint may be used in place of spot welds, TOX joints or other metal joining mechanisms that would prohibit the panel assembly from being used in certain applications, such as class A surfaces on a vehicle that can be seen or touched by a customer.
A welded blank assembly (200) includes a capping material (210) in a weld region (220) of the assembly. The capping material can help protect a weld joint (208) joining first and second sheet metal pieces (12, 112) together. At least one of the sheet metal pieces has a coating material layer (18) that is removed prior to forming the weld joint so that the coating material does not contaminate the weld joint. The removed coating material can be collected before the weld joint is formed and reapplied as part of the capping material after the weld joint is formed, effectively changing the coating material from a potential weld contaminant to a weld joint protectant. The capping material may also include additional material from a source other than the coating material layer.
An energy absorbing assembly, sometimes referred to as a crush tip assembly, that is mounted to a body-on-frame vehicle, either behind a front or rear bumper, so that the assembly absorbs energy in during a collision. The energy absorbing member is a multi-piece assembly where adjoining segments are secured together with a welded joint that may include a non-linear portion having one or more junction features. The specific arrangement of the non-linear portion, along with other optional secondary features like strengthening ribs, holes, slots, etc., can be used to achieve more desirable energy profiles during a collision event.
B60R 19/18 - Means within the bumper to absorb impact
B62D 21/15 - Understructures, i.e. chassis frame on which a vehicle body may be mounted having impact absorbing means, e.g. a frame designed to permanently or temporarily change shape or dimension upon impact with another body
A modular assembly having a press-fit fastener hole. The press-fit fastener hole may include a plurality of lobe regions and a plurality of contact regions that may be spaced between lobe regions for a press-fit engagement with a fastener. The fastener may have a first diameter and the contact regions collectively may define an imaginary second diameter that is less than or equal to the first diameter.
Sheet metal pieces intended to be welded can be made with weld notches located along one or more edges. A. weld notch (30) is characterized by the absence of certain material constituents (16, 18) so that they do not unacceptably contaminate nearby welds. The weld notch can be created by first forming an ablation trench (130) along the sheet metal piece (12), then separating the sheet metal piece along the formed ablation trench into two separate pieces, at least one of which includes a newly formed and weldable edge (28).
A welded blank assembly (140) is formed by welding edge regions (120, 120') of separate sheet metal pieces (112, 112') together at a weld joint (148). One or more of the sheet metal pieces includes a coating material layer (118) and a weld notch (130, 130'), where at least some of the coating material layer is removed from the edge region(s) prior to welding so that the weld joint is substantially free from constituents of the coating material layer. An additional material (156, 158) may be added to a weld pool (144) during weld joint formation to influence the size, shape and/or composition of the resulting weld joint to help compensate for the presence of the weld notch.
A sheet metal piece (12) includes a base material layer (14) and one or more intermediate and coating material layers (16, 18), along with a weld notch (30) formed along an edge region (20) of the piece. At least a portion of the coating and intermediate material layers is removed at the weld notch so that certain constituents from such layers do not affect the integrity of a nearby weld joint (22) when it is subsequently formed along the edge region. Various methods of ablation, including laser ablation, can be used to form the weld notch.
A panel assembly (10) with a multi-layer patch (14) may be used in any number of different applications in order to reduce noise or vibrations, provide thermal insulation, and/or improve the structural integrity of an underlying part. In an exemplary embodiment where the panel assembly is a vehicle part, the panel assembly (10) includes a main panel (12), a primary adhesive layer (16), and a multi-layer patch (14) that includes at least two individual patches (24, 26, 28) and at least one auxiliary adhesive layer (30, 32). The primary adhesive layer attaches the multi-layer patch to the main panel, and the auxiliary adhesive layer attaches the individual patches together. The size, shape, thickness and/or composition of the different layers of the multi-layer patch may be specifically chosen to exhibit certain sound and/or thermal damping properties.
A panel assembly (10) for use in any number of different applications, including a variety of vehicle applications, that reduces noise or vibrations, provides thermal insulation, and/or improves structural integrity. According to an exemplary embodiment, the panel assembly (10) includes a main panel (12) made from a metal, one or more sound damping patches (14, 16) also made from a metal, and an adhesive layer (18) that joins the patches (14, 16) to the main panel (12) in a constrained layer construction. The sound damping patches (14, 16) may include one or more forming features (30, 32), which are designed to improve the formability of the panel assembly (10) without significantly impairing its sound damping characteristics. There are different types of forming features, including internal forming features (30) (e.g., openings, holes, slits, slots, etc.) located within the interior of the patch and external forming features (32) (e.g., projections, fingers, recesses, waveforms, etc.) located along the perimeter of the patch.
A high-pressure fuel injection pump (10), including a sound-damping acoustic cover (30), is mounted on an engine (12) and is part of a direct-inject fuel system for a vehicle. In an exemplary embodiment, the acoustic cover (30) includes a top portion (40) that fits over the fuel injection pump (10) and a side portion (42) that mechanically engages the fuel injection pump (10), and at least one of the top or side portions (40, 42) is formed from a sound-damping metal laminate material (50). Sound and/or vibrations that emanate from the fuel injection pump (10) may be transferred to the acoustic cover (30) and converted into thermal energy by the sound-damping metal laminate material (50).
A vehicle floor tub is generally designed for attachment to a vehicle floor panel and may have a variety of uses. In one embodiment, the vehicle floor tub may include a sound damping patch applied to the base of the tub for improved vibration or sound damping purposes, thermal insulation, added structural integrity, etc. The vehicle floor tub may include a main panel, a sound damping patch, and an adhesive layer that are formed together from a main blank, a sound damping blank, and an adhesive layer. The sound damping patch may include one or more forming features located near complex stress regions. In one embodiment, the vehicle floor tub may be sized and configured to be a vehicle seat tub that is located in the floor of a vehicle and accommodates a folded or collapsed vehicle seat; in another embodiment, the vehicle floor tub may accommodate a spare wheel
A multi-layer assembly, such as a sound damping metal laminate used in the automotive industry, having first and second rigid layers and an adhesive layer in between. A retention feature in the form of a raised embossment may be formed in one or more of the rigid layers and may be located near a fastening hole, which accommodates a nut and bolt or some other type of fastening device. The retention feature may impart rigidity and improved stiffness to the multi-layer assembly in the area surrounding the fastening hole, and it may also create a space between the rigid layers that is generally devoid of adhesive from the adhesive layer. This, in turn, can improve the long term performance of the multi-layer assembly by addressing issues such as compression set, spring back and/or stress relaxation. Methods of manufacture and other embodiments are also provided, including ones that accommodate multiple fastening holes, have discontinuous retention features, and use welds in place of nuts and bolts, to name a few.
G10K 11/16 - Methods or devices for protecting against, or for damping, noise or other acoustic waves in general
G10K 11/168 - Plural layers of different materials, e.g. sandwiches
B32B 15/04 - Layered products essentially comprising metal comprising metal as the main or only constituent of a layer, next to another layer of a specific substance
B32B 37/12 - Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by using adhesives
A metal panel assembly (10, 110) that may be used in a number of different applications, particularly those that are concerned with improved stiffness and/or reduced vibration and noise. According to an exemplary embodiment, the metal panel assembly has a multi-layer or sandwich construction and includes a metal body layer (12, 112), a sound damping adhesive layer (14, 114), and a metal outer layer (16, 116). The outer layer is bonded to the body layer via the adhesive layer and improves the stiffness and/or reduces vibrations in the metal panel assembly. The outer layer may include a number of contact sections (42, 142) that confront the body layer through the adhesive layer, as well as a number of raised sections (44, 144) that are spaced from the body layer and increase or otherwise improve the stiffness of the metal panel assembly. In one embodiment, the raised sections (44) resemble channels and are generally arranged in a column-like pattern; in another embodiment, the raised sections (144) resemble ribs and are generally arranged in a grid-like pattern.
B32B 15/08 - Layered products essentially comprising metal comprising metal as the main or only constituent of a layer, next to another layer of a specific substance of synthetic resin
B32B 37/12 - Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by using adhesives
C09J 5/06 - Adhesive processes in generalAdhesive processes not provided for elsewhere, e.g. relating to primers involving heating of the applied adhesive
27.
APPARATUS, SYSTEM AND METHOD FOR MANUFACTURING METAL PARTS
An apparatus, system and method for manufacturing metal parts, where input material is received from several material sources, multiple metal parts are produced at the same time, and the multiple metal parts may be provided to a downstream operation for subsequent processing. According to an exemplary embodiment, unwinding apparatuses (12, 14, 16) unwind metal coils (36, 38, 40) and provide three separate metal strips (30, 32, 34) to coil-fed metal forming press (18). The coil-fed metal forming press (18) then creates three separate blanks or metal parts (48) at the same time. Next, a part transfer apparatus (20) retrieves the three metal parts (48) from an output side of coil-fed metal forming press (18), and presents them to part assembly apparatus (22), which may include a laser welder or other piece of equipment. Once the metal parts (48) are properly positioned, part assembly apparatus (22) can create a metal part assembly (50) from the three individual blanks.
B21D 43/05 - Advancing work in relation to the stroke of the die or tool by means in mechanical engagement with the work specially adapted for multi-stage presses
B23P 23/00 - Machines or arrangements of machines for performing specified combinations of different metal-working operations not covered by a single other subclass
A metal forming process and welded coil assembly (100, 130, 160) that may be used to form complex metal components in a manner that is efficient, reduces scrap material, and maintains the structural integrity of the components. Generally, a number of individual metal blanks (102, 132, 162) are welded to one or more sheet metal coils (104, 106, 134, 164, 166) in order to produce a welded coil assembly. The metal blanks may be welded along the length of the inner sides of two sheet metal coils, or the metal blanks may be welded along the length of the outer sides of a single sheet metal coil, to cite a couple of possibilities. The welded coil assembly can then be fed through a progressive stamping apparatus (180) or other machine to create a complex metal part (188, 190, 198, 200).
B21D 22/02 - Stamping using rigid devices or tools
B21D 31/00 - Other methods for working sheet metal, metal tubes, metal profiles
B23K 31/02 - Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by any single one of main groups relating to soldering or welding
A method of producing a composite component (10) that includes both a structural insert (12) and a plastic casing (14). According to an exemplary embodiment, the method uses a closed- loop control system and includes the following steps: evaluating the structural insert (12) for various attributes, placing the structural insert (12) in a mold cavity (62), adjusting the position and/or orientation of the structural insert (12) with respect to the mold cavity (62) based on, among other things, the evaluated attributes, and injecting molten material into the mold cavity (62) so that it at least partially surrounds the structural insert (12).
A metal blank (10, 100, 210) that includes a binder trim component (40, 240) having at least one cut edge (24, 26, 102) with a non-linear section (250). The creation of the nonlinear section (250) simultaneously forms a corresponding section in a binder trim component of an adjacent metal blank so that binder material can be shared therebetween. This reduces the amount of scrap metal, as the binder trim component (40, 240) is subsequently cut off and discarded. Furthermore, the non-linear section (250) can include one or more strategically placed formations, such as projections (50, 60, 104, 246, 248, 252, 260), recesses (52, 62, 106, 254, 262, 266, 268), flat sections (256, 258), etc., that cause it to be non-uniform along its length and to be specifically tailored to the manufacturing requirements of the part being formed.
A metal framing member (12) for use in a wide variety of applications including interior and exterior walls, structural insulated panels (SIPs), as well as floors, ceilings and roofs of residential and commercial buildings, to name but a few. The metal framing member generally includes first and second metal components (20, 22), where each of the metal components is a separate piece and includes an elongated support (30) with a series of fingers (34) extending therefrom. The two metal components are attached together near tips (52) of the fingers so that an alternating sequence of fingers and spaces (34, 36) is formed in an intermediate area between the two supports. This sequence can result in weight, material and cost savings, reduced thermal and acoustic conductivity across the metal framing member, and trade-ready holes for passing through items such as wires, pipes, etc.
E04C 3/08 - JoistsGirders, trusses, or truss-like structures, e.g. prefabricatedLintelsTransoms of metal with apertured web, e.g. with a web consisting of bar-like componentsHoneycomb girders
E04B 2/60 - Walls of framework or pillarworkWalls incorporating load-bearing elongated members with elongated members of metal characterised by special cross-section of the elongated members
