A method to prepare a composite laminate object containing an extrusion grade 7xxx Al substrate and a fiber-reinforced polypropylene layer adhesively laminated to the substrate; is provided. The process includes shaping and cutting an extruded 7xxx aluminum to a profile, assembling a layered arrangement of the 7xxx Al profile as substrate, an adhesive film and a fiber reinforced polypropylene preform, heating the layered arrangement to a temperature of 160-175 C. to melt the polypropylene and activate the adhesive film, applying pressure to at least a surface of the fiber reinforced polypropylene preform to mold the preform to the shape of the extruded 7xxxAl substrate and obtain a semi-finished laminate object, cooling the semi-finished laminate object to 90 C., optionally, cooling the semi-finished laminate object to room temperature for inventory storage; heat treating the semi-finished laminate object at 90 C. for 2 to 8 hours; and then heat treating the semi-finished laminate object at 130 C. to 150 C. for 8 to 16 hours; and cooling the heat treated object to obtain the composite laminate object.

An exemplary impact beam for a vehicle includes a body defining a longitudinal axis of the impact beam. The body has a first longitudinal surface laterally separated from a second longitudinal surface, a first end including a first extension and a second extension such that the first and second extensions form a T-shape with the first and second longitudinal surfaces of the body, and a second end opposite the first end, the second end including a first extended portion and a second extended portion connected to the first extended portion by a connecting surface. The first extended portion is configured to extend into a first crush space defined by a fascia of the vehicle and the second extended portion is configured to extend into a second crush space defined by the fascia of the vehicle.

A vehicular structure includes: a first member formed in a tubular shape and having protrusions on an outer periphery thereof; and a second member formed in a tubular shape and having a locking wall with a hole in which the first member is inserted. The first member is joined to the second member such that a portion of the first member that is inserted in the hole of the second member is expanded, and the protrusions are in contact with the locking wall of the second member.

A crash management system for a vehicle having a longitudinal direction X a transverse direction Y perpendicular to the longitudinal direction X and a vertical direction Z perpendicular to the plane defined by said directions X and Y, comprising a bumper cross member globally oriented in said transverse direction Y, at least a longitudinal member arrangement, at least a crash extension attached to at least one of the ends of said bumper cross member and extending over a predetermined length behind said bumper cross member in the longitudinal direction wherein said crash extension is a hollow profile having at least one chamber and having at least one flange attached on said bumper cross member, wherein said flange bends in the event of a deformation of the end portion of said bumper cross member following a collision of the vehicle, in particular a collision with small overlap.

A method for joining a first part formed of an aluminum material to a second part formed of a steel material by metal inert gas welding and cold metal transfer is provided. An aluminum filler material forms a fillet joint between the parts and provides a structure for automotive body applications, such an aluminum bumper extrusion joined to a steel crush box connection. The first part includes a notch for hiding the start and end of the joint. A transition plate formed of a mixture of aluminum material and steel material can be disposed between the first part and the second part to provide the notch. The second part can include a mechanical fastener further joining the parts together. In another embodiment, the second part includes a plurality of dimples and is welded to the first part along the dimples.

A shock absorbing structure for a vehicle 1 is provided which includes a bumper beam 67 connecting together a pair of shock absorbing members 61, 61 made of a fiber-reinforced resin. The shock absorbing member 61 includes an upper wall portion 62a, a lower wall portion 62b, a side wall portion 62c having a recess 63, an upper flange portion 62d, and a lower flange portion 62e, and a vehicle-width-direction outer side is open. An outer edge portion 62o extends in a front-rear direction, an inner edge portion 62i extends in an inclined manner, and a width of each of the upper wall portion 62a and the lower wall portion 62b is wider on a rear side than a front side. Step portions 64 make an interval between the upper wall portion 62a and the lower wall portion 62b become narrower on a vehicle-width-direction inner side than the vehicle-width-direction outer side.

A method for warm forming an aluminum beam, such as an aluminum component for a vehicle, includes providing an extruded aluminum beam with a hollow cross-sectional shape. A portion of a forming die is heated to a desired temperature, so as to heat a portion of the aluminum beam in the die to a temperature below the artificial aging temperature of the aluminum beam. The heated aluminum beam is deformed to a desired shape with the die in a direction transverse to a length of the aluminum beam.

The invention relates to a bumper (10) for a motor vehicle, with a cross beam element (30) exhibiting a back side (22) designed to be fastened to the motor vehicle with at least one fastening device (25), preferably in the form of a crash box, and a front side (21) lying opposite the back side (22), wherein the cross beam element (30) has at least one hollow chamber (36, 37) with a closed cross section, and with a reinforcing element (40; 40a), which extends over part of the length of the cross beam element (30) and is joined with the cross beam element (30). The invention provides that the cross beam element (30) be designed together with the reinforcing element (40; 40a) as a single-piece extruded part.

A load distribution device for a vehicle configured to distribute loads in the event of a collision involving the vehicle, the load distribution device comprises: an upper beam extending in a transversal direction and connectable to at least one upper load path of the vehicle; a lower beam extending in the transversal direction and arrangeable at at least one lower load path of the vehicle; and an interconnecting portion connecting the upper beam and the lower beam, wherein the upper beam, the lower beam, and the interconnecting portion are made in a single piece.

A structural member includes an inner member and an outer member formed of a material different from that of the inner member, the outer member being positioned outside the inner member so as to surround the inner member and including a first adjacent surface adjacent to an outer surface of the inner member, wherein an insulator is disposed between the first adjacent surface and a second adjacent surface of the inner member, the second adjacent surface being adjacent to the first adjacent surface.