A galvanized reinforcement beam is continuously formed by uncoiling a roll of galvanized sheet stock in a generally horizontal plane. Protrusions are formed at an upper surface of the sheet stock, which is then roll formed to form a tubular shape with the protrusions abutting a surface of the sheet stock to form venting gaps. The sheet stock is laser welded at the protrusions to continuously form a weld joint, where zinc oxide gas generated from the welding is permitted to escape an interior of the tubular shape through the venting gaps.

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 walls 11 and 12, each of which includes a high-strength portion 11A, 12A with a yield strength not lower than 500 MPa 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 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.

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 bumper beam structure includes a bumper beam that extends in the vehicle-width direction and that has a closed section formed by an outer vertical wall, an inner vertical wall, a top member, and a bottom member and a reinforcing member that is mounted inside the closed section of the bumper beam at the center in the vehicle-width direction of the bumper beam. The reinforcing member has a pair of angled members that diverge in the vehicle-width direction from the outer vertical wall toward the inner vertical wall and, in a minor collision, causes an impact load to act as a tensile force on the inner vertical wall of the bumper beam through the angled members. The angled members are spot-welded to the bottom member with mounting surfaces therebetween. In a major collision, spot welding points fracture after the bumper beam collapses, thereby absorbing impact energy.

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 vehicle frame member includes a first wall portion formed into a band plate shape extending in a predetermined direction, a second wall portion and a third wall portion formed into a band plate shape extending in the predetermined direction, the second wall portion and the third wall portion extending in a first direction and in a second direction, respectively, from opposite ends of the first wall portion in a width direction of the first wall portion. Respective recessed groove portions extending in the predetermined direction are formed on respective outer surfaces of the second wall portion and the third wall portion.

A bumper crossmember comprising a wave structure oriented in the vertical direction (z direction), wherein the wave structure comprises at least three apex structures which extend in the bumper crossmember longitudinal direction and are adjacent in the vertical direction. This crossmember comprises a first length section that follows its longitudinal extent, at least one second length section that follows its longitudinal extent, and at least one transition section that is arranged respectively between these length sections. In the second length section, the wave structure is inverted with respect to the first length section, in that the opening direction of the apex structures switches in the transition section. In the transition section, there is at least one additional apex-forming structure, the apex of which is offset in the frontal direction (x direction) with respect to a frontal plane (yz-plane) in which at least two apex structures that are adjacent in the longitudinal sections lie.

A bumper beam is made of at least one rolled formed steel sheet containing 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, each of the front walls of the upper beam and of the lower beam containing a front rib extending transversally and towards the interior of the bumper beam. At least one of the upper wall of the upper beam, the lower wall of the lower beam, the rear wall of the upper beam and the rear wall of the lower beam further containing a rib extending transversally and towards the interior of the bumper beam.

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.