A panel assembly is formed by a plurality of bonds between two sheet materials in a face to face relationship to form a preform. The plurality of bonds define a closed perimeter region between the two sheet materials and an open perimeter region between the two sheet materials. The preform may be formed into a predefined shape. Pressurized fluid is applied through an inlet into the open perimeter region to expand the preform. The pressurized fluid expands the open perimeter region such that the two sheet materials expand in an opposing direction, thereby defining an expanded open perimeter region. The closed perimeter region between the two sheet materials remains vacant of the pressurized fluid such that the closed perimeter region is not expanded. The expanded open perimeter region is filled with a filler material for improving a performance characteristic of the panel assembly, e.g., strength, sound absorption, or stiffness.

The invention provides manufacturing a partially reinforced press formed product with high corrosion resistance and antirust property without grain boundary cracks due to spot welding. First and second galvanized steel plates are heated to an austenite range temperature to transform the bodies of the first and second galvanized steel plates into austenite and form a zinc oxide film and a FeZn solid solution phase on the surfaces of the first and second galvanized steel plates. Hot press forming is then performed to the first and second galvanized steel plates which are heated in the process mentioned above, the first and second galvanized steel plates being superposed. The first and second galvanized steel plates, which are hot press formed, are then welded.

A method for mar manufacturing a semifinished product or part is disclosed in which a metal support embodied as a metal sheet or blank is covered with at least one prepreg containing a thermally cross-linkable thermosetting matrix with endless fibers, the thermosetting matrix of the prepreg is pre-cross-linked by means of heating, and the metal support covered with the pre-cross-linked prepreg is formed into a semifinished product or part by means of deep drawing or stretch deep drawing. In order to enable plastic deformation in fiber-reinforced regions of the metal support, it is proposed that during the pre-cross-linking of the thermosetting matrix of the prepreg, its matrix is transferred into a viscosity state that is higher than its minimum viscosity and prior reaching its gel point, the prepreg is formed together with the metal support.

A manufacturing method of press-molded article of the present invention comprises a step of placing a member to be pressed in a press molding apparatus and a step of pressing a flat plate portion of the member to be pressed by bringing a first press portion and a second press portion closer to each other. A first opposing surface and a second opposing surface, while facing to each other, keep in contact with the flat plate portion during pressing. In the press step, a thick part is formed on the flat plate portion by allowing a part of a material of the flat plate portion to flow, in a press direction, into a thickened portion-forming section formed on the first opposing surface. The second opposing surface is moved to the press direction as the flat plate portion is pressed by the first press portion and the second press portion.

A method for manufacturing a semifinished product or component is disclosed in which a metal support embodied as a split strip is covered with at least one prepreg containing a thermally cross-linkable thermosetting matrix with endless fibers, the thermosetting matrix of the prepreg is pre-cross-linked by means of heating, and the metal support covered with the pre-cross-linked prepreg is formed into a semifinished product or component by means of roll forming, in order to enable plastic deformation in fiber-reinforced regions of the metal support, it is proposed that during the pre-cross-linking of the thermosetting matrix of the prepreg, its matrix is transferred into a viscosity state that is higher than its minimum viscosity and prior to reaching its gel point, the prepreg is formed together with the metal support.

A method of manufacturing a large- or medium-sized wheel disk including using a punch or die in a first step of ironing a blank of a flat plate to a first-stage product. The first-stage product having a cylindrical rising portion with an axially non-constant thickness. The rising portion includes a thick portion located at a tip portion of the rising portion and a thickness-reduced portion which is a remaining portion of the rising portion excluding the thick portion. During the first step, only a portion of the blank corresponding to the thickness-reduced portion is ironed.

A method for producing a motor vehicle component from a lightweight metal alloy is disclosed including extruding a profile having at least two wall thicknesses that are mutually dissimilar in the cross section, rolling the extruded profile in portions in the extrusion direction. The rollers in the roller spacing thereof are variable. Cutting-to-length the extruded and in portions rolled profile so as to form a semi-finished product, and forming the semi-finished product so as to form the motor vehicle component.

A frameless dump trailer is provided. The frameless dump trailer includes a forward body portion and a rear body portion. Each body portion is formed from two or more panels joined together with butt-joint welds. The forward portion is first formed by welding planar sections together. After the body portion is formed from the plurality of planar panels, the larger planar portion is rolled in a rolling system to define the arcuate shape of trailer body. Then, the forward and rear body portions are welding together with a transversely extending butt-weld.

A method and system for flanging a metal part is provided to improve the final dimensions of the part to a desired shape. Residual stresses from flanging operations can distort a final shape of the metal part. This disclosure provides an initial flanging step in which metal gainers are formed into the metal during a first flanging step. The metal gainers provide an increased amount of metal at select regions. Then, during a next flanging step, the metal gainers are smoothened or removed during that flanging step while the metal is additionally bent. The metal gainers help combat the residual stresses and allow the flange to better take the desired shape.

A cutting method using a stamping press according to the present disclosure is a method to cut a workpiece that is configured from a first metal sheet and a second metal sheet joined at a weld portion and that has a heat-affected zone around the weld portion, in which the workpiece is cut using a punch. The punch includes a flat portion and a projecting portion projected more toward the workpiece than a flat portion of the punch. The workpiece is positioned with respect to the punch at a position such that the projecting portion starts cutting at least at one out of the heat-affected zone or the weld portion before the flat portion cuts the workpiece. The workpiece is then cut by moving the punch and a die relative to each other in this state of positioning so as to shear across the weld portion on the workpiece.