This invention provides process for manufacturing a galvanized metal three-dimensional object with a shape including multiple edges, said process comprising, in the following order, the steps of: (A) providing and cutting a metal sheet matrix with a thickness within a range from 0.8 mm to 6 mm, the shape of said metal sheet matrix including multiple free edges, (B) batch-wise hot dipping said metal sheet matrix into a molten zinc alloy galvanizing bath, (C) cold-forming the galvanized metal sheet matrix into a desired three-dimensional shape including multiple adjacent metal edges, and (D) cold-forming a series of joining points for fastening together said multiple adjacent metal edges, to form said galvanized metal three-dimensional object.

The end portion of a first member includes a plate part and a groove. The end portion of a second member includes an edge and two side surfaces. The groove extends around the edge of the second member and the two side surfaces. The groove includes a side surface including an engaging portion. One of the side surfaces of the end portion of the second member includes an engaged portion. A method for manufacturing a swaged structure includes preparing the first member including the plate part and the groove having a wide opening. The method further includes inserting the end portion of the second member into the groove after preparing the first member. The method further includes pressing the plate part in a direction narrowing the opening of the groove to bring the engaging portion into contact with the engaged portion after inserting the second member.

Equipment for manufacturing a separator plate for a fuel cell, according to an embodiment of the present disclosure, includes: a first uncoiler uncoiling a first metal strip; a second uncoiler uncoiling a second metal strip; a press receiving the first metal strip and the second metal strip to respectively form patterns thereon; a welding machine overlapping and integrally bonding the first metal strip and the second metal strip, transferred from the press, by a welding process; and a cutter cutting a bonded body of the first metal strip and the second metal strip, transferred from the welding machine, wherein the press, the welding machine, and the cutter are sequentially arranged, and the first metal strip and the second metal strip are passed through the press, the welding machine, and the cutter, while connected to each other, to be processed.

A crash structure for a vehicle includes a crash can having a plurality of indents and a support rail aligned longitudinally with the crash can. The support rail has an inboard surface region having a further indent to facilitate inward deformation of the crash structure, and an opposite surface region having a continuous surface opposite the further indent. A method of manufacturing a crash structure is also provided.

A crash structure for a vehicle includes a crash can having a plurality of indents and a support rail aligned longitudinally with the crash can. The support rail has an inboard surface region having a further indent to facilitate inward deformation of the crash structure, and an opposite surface region having a continuous surface opposite the further indent. A method of manufacturing a crash structure is also provided.

A method for connecting two components. The method includes heating a deformation region of at least one component part to provide complete heating. The at least one component part is plastically deformed after the complete heating of the deformation region.

A sheet metal component such as a car door is disclosed. The component includes an outer metal sheet having a groove formed therein, and an inner metal sheet having an edge forming a flange received into the groove. A filling material layer is inserted into the groove between the outer metal sheet and the flange. The outer metal sheet and the flange are welded to one another in holes of the filling material layer.

Thermal strain due to welding occurs when long materials having a U-shaped cross section are joined together. The joining work is complicated. To an end portion of a first groove-shaped member having a shape in which side surface portions rise from both ends of a bottom surface portion, that is, a substantially U-shaped cross section, an end portion opposing thereto of a second groove-shaped member having the same shape is fitted. Their bottom surface portions and their side surface portions are kept in close contact with each other. A bottom surface clinched portion is formed on the bottom surface portions in the fitted portions by spot clinching. A pair of edge folding portions are formed on each of the pairs of the side surface portions by hemming bending. Furthermore, a side surface clinched portion is formed on each of the edge folding portions by spot clinching. These three kinds of processing are performed in a single processing step of metal dies. The joining strength is increased and occurrence of thermal strain is eliminated, and efficient joining work can be performed.