Application of stainless steel in crash structures of vehicles

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Application of stainless steel in crash structures of vehicles

Friesen, F. / Cunat, P.J.

The first part of the investigation deals with a simple material substitution from carbon steel to stainless steel for the side member. In this case the possible weight reduction with stainless steel is 9 % (2b condition) to 28 % (cold worked condition). Then the original multipart side member is redesigned to a one part hydroformed beam. Advantages of hydroformed side members are the reduction of parts, the saving of the package space of the flanges which allows an enlarged cross section and for the same reason a more straight design. This promotes crushing instead of buckling and therefore it improves the energy absorption capability. The possible weight reduction with stainless steel and with the new side member design is 19% (2b condition) to 30% (cold worked). In the second part of the study the bumper beam is analysed. A pedestrian friendly design made of stainless steel with a reduced cross section area and therefore a 16 mm reduced thinkness (original: 74 mm; stainless steel design: 58 mm) is developed. The bending stiffness of the stainless steel beams is as high as in the original beam. Even considering pedestrian protection a weight reduction of 39 % is possible. This is achieved by a redesign and a stainless steel material substitution.