A multi-tubular beam for a vehicle, such as a vehicle structure or a bumper reinforcement, includes an elongated beam formed with a metal sheet. The metal sheet has a central section and outer sections extending along a length of the metal sheet. The outer sections are disposed in opposing directions from the outer edges of the central section to provide adjacent first and second tubular portions. The central section forms a common center wall between the adjacent first and second tubular portions. A first edge portion of the metal sheet is disposed along and in parallel alignment with the center wall. The first edge portion is attached to the center wall at a first weld joint to form the first tubular portion. The first weld joint includes a weld material that extends through a thickness of the center wall and into a thickness of the first edge portion.

A hybrid bumper assembly for a vehicle includes a steel reinforcement beam and aluminum crush cans attached to end portions of the steel reinforcement beam. The reinforcement beam has a multi-tubular shape that is formed by a high-strength steel sheet that is roll formed to provide at least two tubular portions. A crush can has an interfacing portion that is coupled to an end portion of the reinforcement beam. The end portions of the reinforcement beam and the interfacing portion of the crush cans may be configured to attach together using a select joining technology in a manner that minimizes or eliminates bimetallic or galvanic corrosion between the reinforcement beam and the crush cans.

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 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.

A structural member (10) includes a closed-cross-section structure having a hat member (1) and a closing plate (2), and a reinforcing member (supplementary strengthening member (SSM)) (4). The hat member (1) includes two side wails (11 and 12), each of which includes a high-strength portion (11A, 12A) with a yield strength not lower than 500 MFa and low-strength portions (11B, 12B) with a yield strength of 60 to 85% of the yield strength of the high-strength portion. As determined along the direction of extension of the ridges (123) of the hat member, both ends of the reinforcing member (4) overlap the high-strength portions (11A and 12B) of the side walls (11 and 12). Adjacent to at least one of both ends of the reinforcing member (4), the border between the high-strength portions (11A and 12A) and the low-strength portions (11B and 12B) is positioned in a region starting at a position 1/3, and ending at a position 3/2, of the height (H) of the side wall (11) distant from that end of the reinforcing member (4) as determined along the direction of extension of the ridges (123) away from the reinforcing member (4).

A bumper beam made of at least one roll formed steel sheet is described. The bumper beam contains an upper beam and a lower beam extending in a transversal direction, the upper beam and the lower beam each having a closed cross-section defined by a front wall, a rear wall, an upper wall and a lower wall, the upper wall and the lower wall joining the front wall to the rear wall, and a central wall extending between the front walls, the rear walls of the upper beam and of the lower beam forming both the lower wall of the upper beam and the upper wall of the lower beam, the central wall extending in at least two different planes.

A method for joining members according to the present invention includes: providing a first member, a second member, a guide shaft member, a rubber member, a first plunger, a second plunger, and a drive mechanism; inserting the second member into a hole portion of the first member; inserting the guide shaft member into a through-hole of the rubber member; inserting the rubber member, into which the guide shaft member is inserted, inside the second member; arranging an assembly in which the first member, the second member, the rubber member, and the guide shaft member so as to horizontally extend; arranging the assembly so as to be sandwiched by the first plunger and the second plunger; and moving the second plunger toward the first plunger; compressing the rubber member by the first plunger and the second plunger in a direction where the guide shaft member extends, and expanding the rubber member radially outside the guide shaft member; and thus expanding and deforming at least a portion of the second member that is inserted into the hole portion to join the portion to the first member by press-fitting.

A vehicle reinforcement beam is roll formed from a metal sheet to provide a multi-tubular reinforcement beam that includes two adjacent tubular sections that share a common center wall. The outer sections the metal sheet extend from opposing ends of the common center wall and are formed to enclose the adjacent tubular sections. An edge portion of the metal sheet that is bent to have a bend radius of about 3-9 mm, where the edge portions attach in abutting and continuous contact with the common center wall to form crevices between the adjacent tubular sections along the first and second faces. A weld is formed in each of the crevices to define crevice ribs in general alignment with and at each of the opposing first and second ends of the common center wall that are configured to improve bending strength and torsional strength of the reinforcement beam.

An exemplary side impact system for a vehicle includes an energy absorption member including a first portion, a second portion, a third portion, and a fourth portion, the first and second portions connected by a first arcuate portion, the second and third portions connected by a second arcuate portion, and the third and fourth portions connected by a third arcuate portion such that the energy absorption member has a W-shaped cross-section and a load path distribution member. The load path distribution member is coupled to the energy absorption member at the first and third arcuate portions.

A vehicle component for a vehicle has a component body which is formed from a core material. The component body has a localized deformation zone which extends flat in the core material, and the deformation zone has a locally variable tensile strength according to a predetermined tensile strength profile configured to influence a deformation profile of the component body upon a force acting on the component body.