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Advanced Vehicle Structure Collision Repair Technologies

Steve Marks

I-CAR Tech Centre

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Who 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

- Vehicle-Specific Contract Training Also Provided

- Curriculum Used In 600+ Technical Schools

- 100,000+ Students Taught Annually

- Recommend Following OEM Procedures

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Passenger Cage Integrity

Correct repair

procedures allow a 5-

Star rated vehicle to

provide 5-Star

protection in a

subsequent collision

event following

collision repair

Newer Technology

Older Technology Courtesy: Insurance Institute

for Highway Safety

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Collision Repair Challenge

Restore Pre-Collision Integrity

Correct repairs will ensure:

- Steel strength/properties are maintained

- Original level of crash protection is restored

- Airbag/restraint performance is maintained

Correct repairs require:

- trained technicians

- correct parts, materials, and equipment

- OEM REPAIR INFORMATION

Courtesy: Insurance Institute for Highway Safety

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OEM Collision Repair Information Benefits

- Ensure safe, high-quality repairs

- Improved brand perception/customer loyalty

- Preserve brand for future owners as used car

- Improved repairability can improve insurance ratings

- Reduce cost of ownership

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OEM Collision Repair Information Elements

- Materials Identification

- Materials identification and repair guidelines

- Tools and equipment requirements

- Position statements

- Vehicle-specific repair procedures

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Steel Identification

2013 Dodge Dart Courtesy Of Chrysler Group LLC

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Courtesy Of Chrysler Group LLC

- LS - Good repairability and weldability (least sensitive to heat). May be

attached using the preferred squeeze-type resistance spot welding

(STRSW) process, weld bonding where appropriate, or MIG welding.

Materials have a tensile strength of less than 270 MPa.

- HS - Some repairability and good weldability (the higher the strength of the

steel, the greater the sensitivity to heat). May be attached using STRSW,

weld bonding, and MIG welding. Material tensile strength range between

270 MPa and 600 MPa and includes DP590.

- VHS - Very limited repairability and weldability (very sensitive to heat).

Attach only at OEM defined locations using OEM defined procedures.

Material tensile strengths are greater than 600 MPa. This category

includes hot-stamped boron materials which are also termed “press

hardened.” Specialized cutters are required with many materials in this

group.

Chrysler Steel Repairability Guidelines

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Pull to straighten inner panels with indirect damage

Section damaged reinforcement and outer panel

Save roof and I/P removal

Conventional Structural Repair

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Advanced Vehicle Structural Repair

- UHSS reinforcements typically not sectioned - replace at factory seams

- Section outer panels to access inner reinforcement factory seams

- Spot weld when two-sided access possible

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Collision Repair Challenges

- UHSS factory seam replacement more common - less sectioning

- Accessing reinforcement factory seams may require removing undamaged outer panels

- No heat during straightening

- Anchoring/pulling issues

- UHSS Spot weld removal

- Laser weld removal

- Spot welding instead of MIG

- MIG brazing

- Dissimilar material combinations

- Multi-layered assemblies

- Panel flange access/stack order

- Restoring corrosion protection in enclosed cavities

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Collision Industry Meeting The Challenges

- Using OEM procedures

- Blueprinting to increase efficiency and accuracy

- Replacing damaged panels when in doubt

- Upgrading equipment

- Obtaining training and weld

qualification

- Becoming capable of:

- Spot welding

- MIG brazing

- Weld bonding/sealing

- Rivet bonding

Courtesy Of ProSpot

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OEM Can Ensure Safe Repairs

- Develop steel identification and repair guidelines

- Standardize steel identification for collision industry

- Develop collision repair procedures and guidelines

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Collision Repair Resources for OEM Engineering

- Society Of Automotive Engineering

- SAE J2376 - New Vehicle Collision Repair Information

- Information requirements for collision repair

- Available from SAE at www.standards.sae.org

- I-CAR and collision industry training will also provide

insight on industry requirements

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I-CAR Advanced Material Repairability Summits

- Ongoing meetings to discuss repairability issues with advanced

materials and design

- Steel Industry, Insurance, Repairers, Trainers, Researchers

- Determine the information needs of the collision repair industry

- Some OEMs providing adequate information - many are not

- Meeting tomorrow May 2nd at AISI in Southfield

- Developing list of required OEM information elements for collision

repair

- OEM participation is essential and welcome

- For information, contact me at steve.marks@i-car.com

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I-CAR Training And Information Sourcing

WWW.I-CAR.COM provides access to:

- Online, Virtual, and Live collision repair

- Links to OEM collision information sites

- A partial-part replacement matrix

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Questions?

THANK YOU!

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North American

Light Vehicle Metallic Material Trends

Great Designs in Steel is Sponsored by:

Use your web-enabled device to download the presentations from today’s event

PRESENTATIONS WILL BE AVAILABLE MAY 3