Importance

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Abstract

A method of forming this vehicle space frame joint is carried out by (1) forming an elongated first member constructed of a metallic material that includes an end segment having a predetermined length and having an exterior surface that defines an exterior configuration of the end segment; (2) forming an elongated tubular hydroformed second member by hydroforming a tubular blank having a tubular metallic wall so as to outwardly deform the tubular metallic wall into a predetermined exterior surface configuration determined by the engagement of the tubular metallic wall with die surfaces of a die assembly, the hydroformed second member having an intermediate segment that includes first and second spaced apart wall portions; (3) forming generally aligned first and second openings within the first and second wall portions, respectively, of the intermediate segment of the second member, the first and second openings being of complimentary configuration to portions of the exterior surface of the end segment of the first member; (4) placing the end segment of the first member through the first and second openings such that portions of the exterior surface of the end segment are in abutting engagement with edge portions of the openings; and (5) welding the intermediate segment and the end segment together in the area of said abutting engagement between exterior surface portions of the end segment and the edge portions of the openings.

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First Claim