Joint structure and method for making a joint structure

Abstract

A joint structure is ideally suited for use in the manufacture of assemblies and subassemblies in aluminum structures. More particularly, the alternative joint structures and methods of forming joint structures facilitate the assembly of a vehicle body-in-white. The friction welded joints of this invention provide assemblies in which lineals and sheet, cast, or extruded components are joined together.

1 . A method of forming a joint for a vehicle body-in-white comprising the steps of: 
 inserting a first component comprising a lineal member having a pair of ends into an opening in a second component having a surface and boss extending from the surface, the opening extending through the boss, such that an end of the boss and the one end of the lineal member are coterminous; and    attaching a cap member onto the coterminous one end of the lineal member and the boss end.    
   
   
       2 . The method of forming a joint according to  claim 1 , wherein said step of attaching the cap member is accomplished by friction welding.  
   
   
       3 . The method of forming a joint according to  claim 1 , wherein a gap is defined between the second component boss and the lineal member, and said method further comprises the step of inserting a sleeve into the gap.  
   
   
       4 . The method of forming a joint according to  claim 3 , wherein the sleeve comprises a non-continuous ring such that a diameter of the sleeve is variable between a maximum and minimum limit.  
   
   
       5 . The method of forming a joint according to  claim 3 , wherein the sleeve has a first face and a second face such that when positioned between the second component boss and the first component lineal member, the second face is proximate said cap member.  
   
   
       6 . The method of forming a joint according to  claim 5 , wherein the sleeve second face defines a discontinuous surface.  
   
   
       7 . The method of forming a joint according to  claim 6 , wherein the sleeve discontinuous second face facilitates a break in the continuity of an interface between the sleeve second face and the cap member during the step of friction welding the joint.