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Advanced Vehicle Design and Advanced High Strength Steel Collision Repair Issues
Steve MarksIndustry Support Manager
I-CAR Tech Centre
Great Designs In Steel 2008
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What Is I-CAR?Inter-Industry Conference On Auto
Collision Repair- Not-For-Profit- Develop and Deliver Collision Repair Training- Conduct Weld Qualification Testing- Skills Training - Welding, Measuring, Sectioning- Train Technicians, Insurance Claims Personnel- Curriculum Used In 600 + Technical Schools- 100,000 + Students Taught Annually- Recommend Following OEM Procedures
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OEM Collision Repair Procedures
- Improved Repairability Can Reduce Insurance Costs- Reduce Number of Total Losses- Reduce Cost Of Ownership- Ensure Repaired Vehicle Is Safe
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Collision Repair ChallengeRestore Pre-Collision Integrity
- Maintain Steel Strength and Characteristics
- Maintain Crash Performance and Limit Intrusion
- Maintain Side Airbag Triggering Timing
- Side Structure Repair CRITICAL TO SAFETY
Courtesy IIHS
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AHSS Collision Repair Issues- Multi-Layered
Assemblies- Restoring Corrosion
Protection- Laser Weld Removal and
Repair Strategy- UHSS Factory Seam
Replacement More Common
- UHSS May Be Embedded In HSS Assembly
- OEM Sectioning Only- Do Not Heat
Laser Weld Removal
GM UHSS Factory Seam Replacement
Multi-Layered Assemblies
OEM Sectioning Only
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AHSS Collision Repair Issues
- MIG Braze Low Strength Outer To UHSS Structure
- STRSW Where Possible - OEM Weld Bond Repair Variables
- Rivet/Rivet Bond- Repair Joining May Differ From OEM Joining
- UHSS Spot Weld Removal- Additional Anchoring - Pulling Damage Challenging- Replace Larger Assemblies- Use Fixtures To Assemble
STRSW and Weld Bond
Multiple Anchoring and Fixtures
Tungsten-Carbide Spot Weld Drill Bits
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Pull To Straighten Inner Panels With Indirect Damage
Partially Replace Damaged Reinforcement and Outer PanelSave Roof and I/P Removal
Conventional Side Impact Repair
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B-Pillar Replacement StrategiesGM UHSS Reinforcements ARE NOT SECTIONED
2008 Buick EnclaveSection HSLA below roof railDP 980 Reinforcement not cut
2008 Chevrolet MalibuReplace DP980 at Roof Rail and Rocker
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Volvo UHSS B-Pillar SectioningVolvo XC 90
Boron Reinforcement Sectioning
MIG Welded Butt Joint Staggered Joints/Three Layers
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Straighten Or Replace?
- Identify Steels For Correct Plan - Repairability Varies With Steel Type- Replace UHSS When Damaged- Cold Straighten Bends If Not UHSS- Repair Limit Criteria Not Documented- Replace HSS When Kinked or
Cracked- Heat Only When OEM Allows
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To Maintain Crash Performance
Identify Steels To Determine Correct Repair
PlanOR
Treat All Steels Like UHSSReplace ALL Damaged Panels, NO StraighteningOld rule - “Treat all steel like HSS” may not apply
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No OEM Steels Identification
- Steel Identifier- Hardness Tester/Convert
Hardness To Tensile Strength - Drilling Welds and Cutting Difficult - Identify Steel By Use or Location
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GM Steel Repair Strategy
- GM Using More AHSS- Steel ID Embedded In Procedure- Stamped Icon On Part- GM Steel Repair Matrix- Available at www.gmgoodwrench.com
2008 Buick Enclave
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GM Repairability Studies
- Joint Effort - N.A. Steel Manufacturing and General Motors- Also Available At WWW.AUTOSTEEL.ORG- Great Designs In Steel 2008 Memory Stick
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Courtesy of General Motors Corporation
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Courtesy of General Motors Corporation
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Identify Steels First - Confusing?
Steel Trade Names May Not Indicate Repairability
- Trade Name/Type:- Dual Phase (HSS/UHSS)- TRIP(HSS/UHSS) - Martensitic (HSS/UHSS)- Usibor - Mega Hard - Boron
HSS repairable - UHSS not repairable
- Strength:- Yield - Tensile
Both are used - may not specify
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Steel Name/Strength Overlap Confusion
Courtesy - AMERICAN IRON AND STEEL INSTITUTE
Identifying the steel by type (DP) alone may be confusingIdentifying the steel by type (DP) alone may be confusingDual PhaseDual Phase 980 980 -- UHSSUHSS Dual PhaseDual Phase 590 590 -- HSSHSS
Example;Mild SteelCan be straightened Can be heated to 1000° F
HSSStraighten bends, replace kinksDo not heat - Cold straighten
UHSSReplace when damaged Use factory seams unless OEM sectioning procedure
Standardize Strength Thresholds and Repair Guidelines
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OEM Can Help Ensure Safe Repairs
- Include Steel Identification In Collision Information- Standardize Steel Identification For Collision Industry- Develop Collision Repair Procedures and Guidelines
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I-CAR and AHSS Repair Issues
- Partial Replacement Matrix at WWW.I-CAR.COM- Advanced High Strength Steel Program at WWW.I-CAR.COM- Steel Unitized Structures Technology and Repair (SPS07)- Compiling Repair Recommendations and Commonalities- Identifying Training Needs For New Skills- Working With Vehicle and Steel Manufacturing Industry-
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Conclusion
Questions ???__________
THANK YOU!!!
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