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This article covers an application of third-generation advanced high-strength steel (3GAHSS) grades to vehicle lightweight body structure development. Design optimization of a vehicle body structure using a multi-scale material model is discussed. The steps in the design optimization and results are presented. Results show a 30% mass reduction potential over a baseline mid-size sedan body side structure with the use of 3GAHSS.

Application of high strength steel (HSS) and advanced high strength steel (AHSS) in automotive vehicle structure has been one of the feasible ways to achieve light weight vehicle. Automotive OEMs continue to engineer body structures with high strength grade steels by reducing component thickness (Gauge and Grade (2G) Optimization) to develop light weight, fuel efficient vehicles. In addition to the 2G optimization, design (Geometry) change of the body structure is also considered as an effective approach of reducing the body structure weight (3G Optimization). However design change lengthens product development time, requires tooling modification and/or new tools design, and increases production time, cost and product-to-market time. Tailored parts (also known as Tailor made parts), where pieces of varying thickness are combined into one part, involving no design change and less tooling requirements, are good alternatives to reduce the weight of the body structure significantly.