Great Designs In Steel 2008

Transcription

1 Great Designs In Steel 2008 Advanced Vehicle Design and Advanced High Strength Steel Collision Repair Issues Steve Marks Industry Support Manager I-CAR Tech Centre

2 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 Technical Schools - 100,000 + Students Taught Annually - Recommend Following OEM Procedures

3 OEM Collision Repair Procedures - Improved Repairability Can Reduce Insurance Costs - Reduce Number of Total Losses - Reduce Cost Of Ownership - Ensure Repaired Vehicle Is Safe

4 Collision Repair Challenge Restore Pre-Collision Integrity Courtesy IIHS - Maintain Steel Strength and Characteristics - Maintain Crash Performance and Limit Intrusion - Maintain Side Airbag Triggering Timing - Side Structure Repair CRITICAL TO SAFETY

5 AHSS Collision Repair Issues Multi-Layered Assemblies GM UHSS Factory Seam Replacement - 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 OEM Sectioning Only

6 AHSS Collision Repair Issues Multiple Anchoring and Fixtures - 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 Tungsten-Carbide Spot Weld Drill Bits

7 Conventional Side Impact Repair Pull To Straighten Inner Panels With Indirect Damage Partially Replace Damaged Reinforcement and Outer Panel Save Roof and I/P Removal

8 B-Pillar Replacement Strategies GM UHSS Reinforcements ARE NOT SECTIONED 2008 Buick Enclave Section HSLA below roof rail DP 980 Reinforcement not cut 2008 Chevrolet Malibu Replace DP980 at Roof Rail and Rocker

9 Volvo UHSS B-Pillar Sectioning Volvo XC 90 Boron Reinforcement Sectioning Staggered Joints/Three Layers MIG Welded Butt Joint

10 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

11 To Maintain Crash Performance Identify Steels To Determine Correct Repair Plan OR Treat All Steels Like UHSS Replace ALL Damaged Panels, NO Straightening Old rule - Treat all steel like HSS may not apply

12 No OEM Steels Identification - Steel Identifier - Hardness Tester/Convert Hardness To Tensile Strength - Drilling Welds and Cutting Difficult - Identify Steel By Use or Location

13 GM Steel Repair Strategy - GM Using More AHSS 2008 Buick Enclave - Steel ID Embedded In Procedure - Stamped Icon On Part - GM Steel Repair Matrix - Available at

14 GM Repairability Studies - Joint Effort - N.A. Steel Manufacturing and General Motors - Also Available At - Great Designs In Steel 2008 Memory Stick

15 Courtesy of General Motors Corporation

16 Courtesy of General Motors Corporation

17 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

18 Steel Name/Strength Overlap Confusion Identifying the steel by type (DP) alone may be confusing Dual Phase UHSS Dual Phase HSS Standardize Strength Thresholds and Repair Guidelines Example; Mild Steel Can be straightened Can be heated to 1000 F HSS Straighten bends, replace kinks Do not heat - Cold straighten UHSS Replace when damaged Use factory seams unless OEM sectioning procedure Courtesy - AMERICAN IRON AND STEEL INSTITUTE

19 OEM Can Help Ensure Safe Repairs - Include Steel Identification In Collision Information - Standardize Steel Identification For Collision Industry - Develop Collision Repair Procedures and Guidelines

20 I-CAR and AHSS Repair Issues - Partial Replacement Matrix at - Advanced High Strength Steel Program at - 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 -

21 Conclusion Questions??? THANK YOU!!!

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