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Application of advanced technology such as tailored blanks, tailored tubes, sheet and tube hydroforming, and extensive laser welding, along with advanced high strength steels and innovative design enabled the ULSAB-AVC (Advanced Vehicle Concepts) Program to achieve outstanding levels of safety, affordability, fuel efficiency and environmental responsibility. This paper describes the advanced technology features of ULSAB-AVC including their design considerations, manufacturing feasibility, and cost impact analysis. The ULSAB-AVC Program is the most recent addition to the global steel industry's series of steel design initiatives. These programs offer steel solutions to the challenges facing automakers around the world today: to increase the fuel efficiency while improving safety, performance and maintaining affordability.

Tensile properties of sheet steels at dynamic conditions are becoming more important for automotives in recent years due to the positive strain rate effect of steels which significantly improves energy absorption capability during crash events. However, several testing techniques are used by different testing laboratories, no testing standards are available, and the quality of data generated by different laboratories is often not comparable. In order to improve the data quality at high strain rate testing conditions and thus to improve the accuracy of crash simulation results, The International Iron and Steel Institute (IISI) initiated a project to develop the “Recommendations for Dynamic Tensile Testing of Sheet Steels”. The document provides guidelines for key elements of high strain rate testing, testing techniques, input methods, specimen geometry and stress/strain measurement instrumentations.

The Strategic Alliance for Steel Fuel Tanks (SASFT), an international group of steel producers and manufacturing companies, recently completed a major corrosion study of various steel ‘systems’ for automobile fuel tanks. The ten steel systems included low carbon steels (either pre-painted or post-painted with protective coatings) and stainless steels. The 2-year corrosion test program included testing in salt solutions to simulate road environments for the exterior of a fuel tank. Special test specimens were designed to represent a manufactured tank. The external tests used were the Neutral Salt Spray test (ASTM B117) with exposures up to 2000 hours and the Cyclic Corrosion test (SAE J2334) with exposures up to 120 and 160 cycles to represent vehicle lives of 15 years and 20 years, respectively. Additionally, the resistance to an aggressive ethanol-containing fuel (internal tank corrosion) was assessed by using uniquely designed drawn cups of the various steel systems.