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2012 Chevrolet Aveo Sedan Body Structure

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The European Chevrolet Aveo is sold in North America as the Chevrolet Sonic.  Sixty percent of the 2012 Chevrolet Aveo Body Structure is made from high-strength steel (HSS colored in yellow).  This includes the engine cradle.  Ultra-high Strength Steel (UHSS colored in red) is strategically integrated in the forward portion of the rockers and the center cross bar.  The engine cradle distributes energy in frontal and side impacts. It is another structural element that helps optimize occupant safety. Together with the front bumper system and the engine compartment rails, the engine cradle bars absorb the brunt of a frontal crash.

Reinforced A and B-pillar help maintain the integrity of the passenger compartment. Should the vehicle roll over in the event of an accident, its roof will be able to withstand forces that equal more than four times the car’s weight.  The Chevrolet Aveo also has a releasable pedal assembly.

 

 

 

2011 Hyundai Genesis Body Structure

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The body structure of the 2011 Hyundai Genesis is made from an Ultra High Strength Steel (UHSS) uni-body.  This is the first line of defense for the passengers inside the Genesis’s cabin.  Hyundai has engineered advanced crumple zones to absorb and redirect forces away from the passenger cabin. 2011-hyundai-genesis-body-structure

Genesis body-in-white is made of the following types of steel: High-strength steel (HSS) (56.7%), shown in green, and Ultra-high-strength steel (UHSS) (18.3%), shown in orange/red. That totals to 75%.

2011 Hyundai Gensis Boron Extrication Body Structure Airbag UHSS

There are 8 airbags in the Genesis, including 2 front, 2 rear seat, dual front-advanced, and roof-mounted curtain side impact bags.   An added safety feature in the seat is the active front head restraints that protect against whiplash in a rear collision.  These whiplash protection systems have started to make there way into more vehicles.  When the systems were first used the cost was too high so you would only find them in high end vehicles.  The systems work very well!

2010 Porsche Panamera Body Structure (UHSS)

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2010 Porsche Panamera Body Structure. The body shell is knitted together from a number of metals. High strength steels, including Boron-alloyed (shown in red), polyphase (orange), and micro-alloyed (yellow) are used to create an ultra-stiff passenger safety cell. The voluptuous rear fenders are very deep draw stampings, which meant they had to be steel (green). At the front is an aluminum subframe (blue) designed to manage front impact loads. The hood, rear hatch, and fenders are also aluminum, as are the doors, which have ultra-lightweight magnesium frames (turquoise).

Scion tC UHSS

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Parts of the body and structure, including the hood, doors, front rails, and inner door aperture, are made of high-strength steel (HSS). The bumper reinforcements and door intrusion beams on the Scion tC are made of UHSS. The UHSS that is used is a thinner gauge than the mild steel.

Ford Flex Boron

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The Ford Flex has a body structure that has been optimized with Boron side intrusion beams in the doors and other strategic use of high-strength boron steel and specially designed. The image below shows the side impact door beams. Ford uses Boron Steel on all vehicles side impact door beams.

The body structure of the Flex uses lightweight aluminum-coated boron steel and High-strength steel comprises the Flex’s B-pillars. Ford also states the use ultra-high-strength steel in the A-Pillars.

Nissan Green Program 2010

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The main reason automakers are using Boron and other Ultra-high Strength Steels is to improve the fuel economy by reducing vehicle weight. The “Nissan Green Program 2010” plans to use High tensile strength steel sheet (HSS) to reduce Body-in-White (BIW) weight. Nissan also plans the use of new 780 & 980 MPa UHSS and its application. Nissan has newly developed Low–Carbon content Dual Phase 780 & 980 MPa steel sheet. Now Nissan is on the way to expanding this UHSS sheet application to BIW globally.

2010 Mazda 3 High-Strength Steel

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Since Mazda is still partly owned by Ford there should be little surprise that the 2010 Mazda 3 is a Volvo-sourced platform. The new Mazda 3 is made up with double the amount of high-strength and ultra-high strength steel.

2010 Lincoln MKT

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The new Lincoln MKT has a safety feature named SPACE or Side Protection And Cabin Enhancement Architecture. SPACE helps optimize side-impact occupant protection. The SPACE system integrates a hydroformed high strength steel tube embedded in the floor that runs the width of the vehicle from B-pillar to B-pillar and along the rocker panels to form a safety cage to help protect passengers in side impact incidents.

A vehicle fire side note, the liftgate on the Lincoln MKT is made up of magnesium and aluminum instead of steel. So full PPE as with any vehicle fire!

2009 Scion xB High-Strength Steel (HSS)

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The 2009 Scion xB uses several different grades of High-Strength Steel (HSS) in the body structure. No Ultra-high Strength Steel.

2009 Scion xd High-Strength Steel (HSS)

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The 2009 Scion xd has a body structure made from High-Strength Steel (HSS). The only Ultra-high Strength Steel used is in the front bumper reinforcement.

2009 Nissan GT-R Ultra-high Strength Steel

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Nissan is just like all the other automakers who want to reduce mass for better performance and fuel economy. The GT-R is a mix high power to low weight. Most of the GT-R structure is made from high strength steel. Parts include the front and rear lower rails and the A-pillars. Ultra-high strength steel is used inside the internal structure of the door to increase occupant safety. Look at the images below to see the structure and where different material is used.

Common terms for Different Metals

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Common terms for different metals:

  • High-strength steel (HSS)
  • Ultra-high-strength steel (UHSS)
  • Aluminum (ALU)
  • Boron steel (BOR)
  • Hydroformed steel (HYD)
  • Magnesium (MAG)
  • Sandwiched steel (SAS)