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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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