Many demands are placed on automotive body structures which influence the material selection process. The impact on safety, manufacturability, and longevity are among the most critical, with each of these balanced against cost and environmental concerns.

Formed sheet metal products experience a complex series of deforming, cutting, and joining before being placed in a body structure, where these components will be subjected to complex loading conditions during the product life cycle. Understanding the failure limits and the conditions which produce failure allows for the design of body structures which can withstand these demands.

Testing helps determine whether a metal is suitable for its intended use. Different tests characterize specific performance aspects. Historically, manufacturers relied on tensile testing to understand metal flow. However, new tests help us understand the behavior of new steel grades and their interactions more thoroughly with new manufacturing technologies.


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High Strain Rate Testing

Three important points collectively highlight the need for high-speed testing:


Bend Testing

Tensile testing cannot be used to determine bendability, since these are different failure modes. Failure in bending


Tensile Testing



Friction and Friction Testing

Friction is a restraining force that limits metal flow resulting from contact with another surface during sheet


Bulge and Dome Testing

Local necking during uniaxial tensile testing limits the characterization of the stress-strain response to true


RSW Joint Performance and Testing

Acceptable weld integrity criteria vary greatly among manufacturers and world regions. Each AHSS user needs to


Process, Microstructure and Fracture Mode of Thick Stack-Ups of Aluminum Alloy to AHSS Dissimilar Spot Joints

This article summarizes a paper entitled, “Process, Microstructure and Fracture Mode of Thick Stack-Ups of