Magnesium hybrid parts and processes

Abstract

A light weight alloy part is molded in a mold containing at least one weldable metal insert, so that portions of portions of the alloy part lap portions of the insert to securely lock the weldable insert to the light weight alloy part. The resulting hybrid part is thus both light weight and weldable to other assemblies and sub-assemblies.

What is claimed is: 
     
         1 . A hybrid part for structural uses, comprising:
 a weldable connecting insert comprising a weldable first material, adapted to be connected to separate structures through one or more welding processes;   a non-consumable structural member comprising a second material having a relatively low metallurgical weldability and also having a lower density than said first material; and   said weldable connecting insert being securely connected to and locked in place relative to said structural member through portions of said second material being formed to lap portions of said insert, whereby said structural member can be welded to other components by welding said weldable connecting inserts to said other components.   
     
     
         2 . A hybrid part in accordance with  claim 1 , characterized in that said weldable connecting insert comprises a plurality of apertures positioned relative to said structural member so as to receive a flow of a portion of said second material, when said second material is in a molten state. 
     
     
         3 . A hybrid part in accordance with  claim 1 , characterized in that said weldable connecting insert comprises one or more beads formed on surfaces of said weldable connecting insert, positioned so as to prevent any of said second material from covering surfaces of said weldable connecting insert which need to be exposed for purposes of facilitating welding of said weldable connecting insert to said separate structures. 
     
     
         4 . A hybrid part in accordance with  claim 1 , characterized in that said second material is magnesium. 
     
     
         5 . A hybrid part in accordance with  claim 1 , characterized in that said weldable first material is a steel. 
     
     
         6 . A hybrid part in accordance with  claim 1 , characterized in that said weldable connecting insert comprises:
 a plurality of apertures extending through portions of said weldable connecting insert for receiving portions of said second material, when said portions are in a molten state; and   a plurality of beads formed on surfaces of said weldable connecting insert, positioned so as to prevent other portions of said second material from covering surfaces of said weldable connecting insert which need to be exposed for purposes of facilitating welding of said weldable connecting insert to said separate structures.   
     
     
         7 . A hybrid part in accordance with  claim 6 , characterized in that said weldable connecting insert further comprises:
 a center insert section having a top plate and extending flanges downwardly extending from opposing sides of said top plate, with said center insert having a subset of said plurality of apertures; and   a pair of opposing side insert sections, each of said side insert sections having a downwardly extending flange and outwardly extending steel wings, and further having a second subset of said plurality of apertures.   
     
     
         8 . A method for forming a hybrid part for structural uses, comprising:
 providing a weldable connecting insert comprising a weldable first material, adapted to be connected to separate structures through one or more welding processes, and placing said insert into a mold;   molding a structural member, comprising a second material having a relatively low weldability and also having a lower density than said first material, in said mold so that portions of said structural member lap portions of said insert to securely lock said weldable connecting insert to said structural member, whereby said structural member can be welded to other components by welding said weldable connecting inserts to said other components.   
     
     
         9 . The method in accordance with  claim 8 , characterized in that said weldable connecting insert comprises a plurality of apertures positioned relative to said structural member so as to receive a flow of a portion of said second material, when said second material is in a molten state. 
     
     
         10 . The method in accordance with  claim 8 , characterized in that said weldable connecting insert comprises one or more beads formed on surfaces of said weldable connecting insert, positioned so as to prevent any of said second material from covering surfaces of said weldable connecting insert which need to be exposed for purposes of facilitating welding of said weldable connecting insert to said separate structures. 
     
     
         11 . The method in accordance with  claim 8 , characterized in that said second material is magnesium. 
     
     
         12 . The method in accordance with  claim 8 , characterized in that said weldable first material is a steel. 
     
     
         13 . The method in accordance with  claim 8 , characterized in that said weldable connecting insert comprises:
 a plurality of apertures extending through portions of said weldable connecting insert for receiving portions of said second material, when said portions are in a molten state; and   a plurality of beads formed on surfaces of said weldable connecting insert, positioned so as to prevent other portions of said second material from covering surfaces of said weldable connecting insert which need to be exposed for purposes of facilitating welding of said weldable connecting insert to said separate structures.   
     
     
         14 . The method in accordance with  claim 13 , characterized in that said weldable connecting insert further comprises:
 a center insert section having a top plate and extending flanges downwardly extending from opposing sides of said top plate, with said center insert having a subset of said plurality of apertures; and   a pair of opposing side insert sections, each of said side insert sections having a downwardly extending flange and outwardly extending steel wings, and further having a second subset of said plurality of apertures.