BACKGROUND

Metal parts for manufacturing are often produced from a substantially flat blank material (e.g. sheet metal) by subjecting the blank to a forming process (e.g. stamping, extruding, etc.) so that the blank is formed into a formed component with a desired contoured shape. In an effort to reduce the weight of these formed components, the gauge (i.e. thickness) of material used in these formed components is reduced. However, in reducing the gauge of the material used in the formed component, the strength and other characteristics of the formed component are reduced or otherwise compromised. In order to address the reduction in strength associated with the reduction in gauge, several methods are used to reinforce the formed components.

Conventional reinforced formed components include adhesive patches (both non-reinforced and reinforced) placed on the component after it is formed; secondary reinforcing structures of dissimilar composition fastened or welded to the blank or to the formed component; or similar materials welded to the blank prior to forming. Examples of reinforcing strategies include adhesive patches used in metal vehicle door outer panels, spot-welded stiffeners in vehicle frame components, tailor welded and tailor rolled blanks in automobile door inner structures, and patches of reinforcing steel that are spot welded to steel blanks prior to forming. Bolt attachment points for high stress components, like door hinges, are often reinforced using thicker sheet material in tailor welded blanks or reinforcement metal plates attached after forming. Other methods for generating formed vehicle components with spatially variable properties include variable quench hot stamping and selective post-forming heat treatments.

To date, a key method of reducing the weight of vehicles has been the use of “down-gauging” sheet metal components or changing to a “lightweight” material such as aluminum from steel. With respect to formed metal components, reducing the gauge of a sheet metal blank has an inherent limitation based upon strength, stiffness, energy absorption, or fatigue properties required for the formed metal component. Although lightweight materials may be less dense than steel, they often have lower strength and are less stiff.

In a similar manner, extruded metal components have a uniform wall thickness, and therefore a uniform strength and stiffness, along the extrusion direction, such that the wall thickness is based on the requirements of the most highly loaded region of the component.

BRIEF DESCRIPTION

According to one aspect, a composite component includes a base component, a reinforcement, and a localized coupling reinforcing, or forming, a bond between the base component and the reinforcement. The localized coupling is arranged only at a discrete location on the base component, and includes a compression of the base component, a fusion weld in the base component, or a heat affected zone of the weld.

In another aspect, a method of making a composite component includes providing a base component and a reinforcement. A localized coupling is formed in the base component to reinforce, or form, a bond between the base component and the reinforcement. The localized coupling is arranged only at a discrete location on the base component. The localized coupling includes a compression of the base component, a fusion weld in the base component, or a heat affected zone of the weld.

