Advanced Vehicle Structure Collision Repair Technologies

Transcription

1 Advanced Vehicle Structure Collision Repair Technologies Steve Marks I-CAR Tech Centre

2 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

3 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 Courtesy: Insurance Institute for Highway Safety Older Technology

4 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 Courtesy: Insurance Institute for Highway Safety Correct repairs require: - trained technicians - correct parts, materials, and equipment - OEM REPAIR INFORMATION

5 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

6 OEM Collision Repair Information Elements - Materials Identification - Materials identification and repair guidelines - Tools and equipment requirements - Position statements - Vehicle-specific repair procedures

7 Steel Identification 2013 Dodge Dart Courtesy Of Chrysler Group LLC

8 Chrysler Steel Repairability Guidelines - 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 DP 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. Courtesy Of Chrysler Group LLC

9 Conventional Structural Repair Pull to straighten inner panels with indirect damage Section damaged reinforcement and outer panel Save roof and I/P removal

10 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

11 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

12 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

13 OEM Can Ensure Safe Repairs - Develop steel identification and repair guidelines - Standardize steel identification for collision industry - Develop collision repair procedures and guidelines

14 Collision Repair Resources for OEM Engineering - Society Of Automotive Engineering - SAE J New Vehicle Collision Repair Information - Information requirements for collision repair - Available from SAE at - I-CAR and collision industry training will also provide insight on industry requirements

15 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 2 nd 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 [email protected]

16 I-CAR Training And Information Sourcing provides access to: - Online, Virtual, and Live collision repair - Links to OEM collision information sites - A partial-part replacement matrix

17 Questions? THANK YOU!

18 North American Light Vehicle Metallic Material Trends PRESENTATIONS WILL BE AVAILABLE MAY 3 Use your web-enabled device to download the presentations from today s event Great Designs in Steel is Sponsored by: