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Dynamic denting properties of aluminum and steel autobody panels have been experimentally measured under controlled conditions. Material, geometric and dynamic factors have been graphically and statistically evaluated to determine design equations. For impact velocities of 20-60 mph and sheet gauges of 0.027-0.040″, dent depths are shown as linear functions of impact velocity. This linear velocity model incorporates sheet thickness, yield strength, density and modulus of elasticity of the alloy used, as well as the geometric shape of the fabricated panel. As an example, for equal dent resistance, a panel of 2036-T4 aluminum would need to be 10-13% thicker than the same panel fabricated from 0.035″ gauge 1010-CQ steel.

This paper compares the construction of an aluminum body with an identical steel body. The design parameters set forth for the steel body governed the overall approach resulting in a realistic comparison between aluminum and steel weight of a body-in-white. The paper discusses specific techniques used in the construction of the aluminum body and outlines areas of difference between aluminum and steel of interest to automotive engineers.