UltraLight Steel Auto Body - Final Report - American Iron & Steel ...

Contents
Preface v
Introduction vii
UltraLight Steel Auto Body Consortium ix
1. Design 1
1.1 Benchmarking 1
1.2 Design philosophy and architecture 3
1.3 Packaging 3
1.4 Styling 6
1.5 Material selection 7
1.6 ULSAB in detail 10
2. Materials and Processes 15
2.1 Materials 15
2.1.1 High strength steel 15
2.1.2 Tailored blanks 16
2.1.3 Steel sandwich 19
2.2 Processes 19
2.2.1 Hydroforming 19
2.2.2 Assembly laser welding 21
3. Manufacturing 23
3.1 Early involvement 23
3.2 Tooling 23
3.3 Analysis 23
3.4 Part validation 24
3.5 Assembly 24
3.5.1 Sequence 24
3.5.2 Adhesive bonding 27
iii