Method of making a two-piece super-plastic formed lightweight aluminum door

摘要

A method of making a vehicle door assembly by assembling a super-plastic formed inner door panel with a super-plastic formed outer panel. A flanging and roll hemming tool are used to form a hem flange to secure the outer door panel to the inner door panel. A room temperature curable two-part epoxy adhesive is used to lock the inner and outer door panels together. The epoxy adhesive is permitted to cure before the assembly is heated in electro-operations or paint ovens. Hinge and striker attachment areas are provided that are not substantially thinned or stretched during the super-plastic forming process so as to preserve the strength of the inner and outer door panels in such areas.