A vehicle body assembly is described herein, including a first structural component and a second structural component. The first structural component may be a roof component or a side panel, and include a first part including a first metal and a second part including a second metal different than th
A vehicle body assembly is described herein, including a first structural component and a second structural component. The first structural component may be a roof component or a side panel, and include a first part including a first metal and a second part including a second metal different than the first metal. The second part is formed on a peripheral edge portion of the first part and defines a mounting flange for the first structural component. The second part is joined to the first part via an ultrasonic additive manufacturing (UAM) interface. The second structural component is including the second metal and is joined to the second part at the mounting flange via a resistance spot weld (RSW) joint.
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1. A multi-material component, comprising: a first component comprising a first material;a second component comprising a second material that is different than the first material; andan insert positioned between the first component and the second component, wherein the insert is joined to the first
1. A multi-material component, comprising: a first component comprising a first material;a second component comprising a second material that is different than the first material; andan insert positioned between the first component and the second component, wherein the insert is joined to the first component via an ultrasonic additive manufacturing (UAM) interface and the second component is secured to the insert,wherein the second component is fusion welded to the insert. 2. The multi-material component of claim 1, wherein the insert comprises a plurality of UAM layers. 3. The multi-material component of claim 1, wherein the second component is resistance spot welded (RSW) to the insert via a RSW joint. 4. The multi-material component of claim 3, wherein a thickness of the insert is based on the RSW joint being formed to exclude any portion of the UAM interface; orwherein the thickness of the insert is based on the RSW joint being formed to include a portion of the UAM interface in a Heat Affected Zone (HAZ). 5. The multi-material component of claim 1, wherein the UAM interface runs along a length of the first component and the insert in a forward and rearward direction or in a lateral direction of a vehicle body. 6. The multi-material component of claim 1, wherein the insert is secured to the first component at a peripheral edge portion of the first component and defines a mounting flange to which the second component is secured. 7. A method for manufacturing a multi-material component, comprising: providing a first component comprising a first material;providing an insert comprising a second material that is different than the first material;joining the insert to the first component via an ultrasonic additive manufacturing (UAM) interface;providing a second component comprising the second material; andjoining the second component to the insert by fusion welding the second component to the insert. 8. The method for manufacturing the multi-material component of claim 7, wherein the joining the second component to the insert includes resistance spot welding (RSW) the second component to the insert via a RSW joint. 9. The method for manufacturing the multi-material component of claim 8, wherein joining the second component to the insert includes forming the RSW joint to include a portion of the UAM interface in a Heat Affected Zone (HAZ). 10. The method for manufacturing the multi-material component of claim 8, wherein joining the second component to the insert includes forming the RSW joint to exclude any portion of the UAM interface. 11. The method for manufacturing the multi-material component of claim 8, wherein a thickness of the insert is based on the RSW joint being formed to include or exclude a portion of the UAM interface. 12. The method for manufacturing the multi-material component of claim 7, wherein the first material is an aluminum or aluminum-based alloy and the second material is a steel or steel-based alloy. 13. The method for manufacturing the multi-material component of claim 7, wherein the first component is a roof component or a side panel. 14. The method for manufacturing the multi-material component of claim 7, wherein the second component is a vehicle body component. 15. A vehicle body assembly, comprising: a first structural component including: a first part comprising a first material; anda second part comprising a second material different than the first material,wherein the second part is formed on a peripheral edge portion of the first part and defines a mounting flange for the first structural component,wherein the second part is joined to the first part via an ultrasonic additive manufacturing (UAM) interface; anda second structural component comprising the second material, wherein the second structural component is joined to the second part at the mounting flange via a resistance spot weld (RSW) joint, and wherein the second part is positioned between the first part and the second structural component. 16. The vehicle body assembly of claim 15, wherein the first material is an aluminum or aluminum-based alloy and the second material is a steel or steel-based alloy. 17. The vehicle body assembly of claim 15, wherein the first structural component is a roof component or a side panel. 18. The vehicle body assembly of claim 15, wherein a thickness of the second part is based on the RSW joint or associated Heat Affected Zone (HAZ) including or excluding a portion of the UAM interface. 19. The vehicle body assembly of claim 15, wherein the UAM interface runs along a length of the first part and the second part in a forward and rearward direction or a lateral direction of the vehicle body assembly. 20. The vehicle body assembly of claim 15, wherein the UAM interface is located at a position corresponding to a region to be welded by resistance spot welding. 21. A multi-material component, comprising: a first component comprising a first material;a second component comprising a second material that is different than the first material; andan insert positioned between the first component and the second component, wherein the insert is joined to the first component via an ultrasonic additive manufacturing (UAM) interface and the second component is secured to the insert;wherein the UAM interface runs along a length of the first component and the insert in a forward and rearward direction or in a lateral direction of a vehicle body. 22. The multi-material component of claim 21, wherein: the insert comprises a plurality of UAM layers; andthe second component is resistance spot welded (RSW) to the insert via a RSW joint. 23. The multi-material component of claim 22, wherein: a thickness of the insert is based on the RSW joint being formed to exclude any portion of the UAM interface, or the thickness of the insert is based on the RSW joint being formed to include a portion of the UAM interface in a Heat Affected Zone (HAZ); andthe insert is secured to the first component at a peripheral edge portion of the first component and defines a mounting flange to which the second component is secured. 24. The multi-material component of claim 22, wherein: a thickness of the insert is based on the RSW joint being formed to exclude any portion of the UAM interface, or the thickness of the insert is based on the RSW joint being formed to include a portion of the UAM interface in a Heat Affected Zone (HAZ); andthe UAM interface runs along a length of the first component and the insert in a forward and rearward direction or in a lateral direction of a vehicle body. 25. A multi-material component, comprising: a first component comprising a first material;a second component comprising a second material that is different than the first material; andan insert positioned between the first component and the second component, wherein the insert is joined to the first component via an ultrasonic additive manufacturing (UAM) interface and the second component is secured to the insert;wherein the insert is secured to the first component at a peripheral edge portion of the first component and defines a mounting flange to which the second component is secured. 26. The multi-material component of claim 25, wherein: the insert comprises a plurality of UAM layers; andthe second component is resistance spot welded (RSW) to the insert via a RSW joint. 27. A method for manufacturing a multi-material component, comprising: providing a first component comprising a first material;providing an insert comprising a second material that is different than the first material;joining the insert to the first component via an ultrasonic additive manufacturing (UAM) interface;providing a second component comprising the second material; andjoining the second component to the insert;wherein the first material is an aluminum or aluminum-based alloy and the second material is a steel or steel-based alloy. 28. The method for manufacturing the multi-material component of claim 27, wherein: joining the second component to the insert includes resistance spot welding (RSW) the second component to the insert via a RSW joint; andjoining the second component to the insert includes forming the RSW joint to include a portion of the UAM interface in a Heat Affected Zone (HAZ), or joining the second component to the insert includes forming the RSW joint to exclude any portion of the UAM interface. 29. The method for manufacturing the multi-material component of claim 27, wherein: the first component is a roof component or a side panel of a vehicle; andthe second component is a vehicle body component. 30. The method for manufacturing the multi-material component of claim 27, wherein: joining the second component to the insert includes resistance spot welding (RSW) the second component to the insert via a RSW joint;joining the second component to the insert includes forming the RSW joint to include a portion of the UAM interface in a Heat Affected Zone (HAZ), or includes forming the RSW joint to exclude any portion of the UAM interface; andthe first material is an aluminum or aluminum-based alloy and the second material is a steel or steel-based alloy. 31. The method for manufacturing the multi-material component of claim 27, wherein the first component is a roof component or a side panel of a vehicle. 32. A method for manufacturing a multi-material component, comprising: providing a first component comprising a first material;providing an insert comprising a second material that is different than the first material;joining the insert to the first component via an ultrasonic additive manufacturing (UAM) interface;providing a second component comprising the second material; andjoining the second component to the insert;wherein the second component is a vehicle body component.
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