Abstract:
A material and method for manufacturing components. The method includes squeeze casting the material into a component of a desired shape and flow-forming the component that has been squeeze cast to refine the shape of the component. The method also includes heat treating the component to enhance the microstructure of the component and machining the component to further refine the shape.
Abstract:
A method for manufacturing an inner door panel for a vehicle side door that employs a die casting process. The method includes providing a die cast mold having opposing mold halves that combine to define a die cavity configured to provide the inner door panel. An impact beam is positioned in the mold cavity prior to combining the first mold half and the second mold half, and a molten metal is provided to the mold cavity so that molten metal flows into all areas of the mold cavity and around the impact beam after the first mold half and the second mold half are combined. A solidified molded inner door panel is then removed from the die cast mold that includes an encapsulated impact beam.
Abstract:
An energy absorber according to various embodiments can include a structure having a predetermined cross-sectional profile. A hollow profile is formed within the structure. The pre-determined cross-sectional profile of the structure is configured based on a deceleration-time profile that includes a first period and a second period. The first period is defined by a substantially sharp and linear increase in magnitude of the deceleration of an impact until a maximum deceleration value is achieved. The second period is defined by a rapid decrease in the magnitude of the deceleration.