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The Future is Forming

Welcome to the Inaugural Newsletter from Engineering Quality Solutions!

Many sites describe the benefits of using high strength steels in a vehicle structure. However, one of the challenges associated with the higher strength and the better designs for crash/crush performance is related to passenger rescue after a crash. The types of cutters and extraction techniques used 10 years ago are insufficient to handle today's designs. This website, www.boronextrication.com is focused on helping firefighters know where advanced high strength steels (AHSS) are used in vehicle structures, and is run by “Smitty,” a metro Detroit firefighter/EMT who also works in the automotive industry designing seat structures and seat adjusters.

I'm always interested in where AHSS is being used. The link below is great post containing a detailed list of vehicles that contain these steels, breaking it down by specific parts where that information is available.

List of Vehicles with Boron and Ultra High Strength Steels
 

The one-piece rear-quarter side panel / fender / door ring on the Acura ZDX was one of the most challenging stampings on the new vehicle. The 320mm deep draw (50% deeper than other Honda-produced panel) combined with an 8mm radius on a character line (tighter than used on other Acura vehicles) made for a lengthy development cycle.



 

Sheet hydroforming was considered, but there were no presses of the right capacity available. Manufacturing the panel as two separate stampings was also considered, with a weld seam in the taillight area and under the rear door cutline, but that approach was rejected. Ultimately, the panel was made in one piece, with additional formability achieved by using a low-friction phosphate coating between the die and the steel panel.


 

Approximately half of the body structure is made from high strength steel, including the A- and B-pillars, floor sills, roof frame, cross braces, and floor cross members. Sheet aluminum is used for about 5% of the body components, including the hood and instrument panel support, typically areas where light weight is desired but strength and stiffness are not overriding requirements.