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Adequacy of resistance spot welds in low carbon steels in relation to structural integrity can become an issue in the reconstruction of automotive accidents. Because formation of a plug (or button or slug) in a peel test is used as a quality control criterion for welds, it is sometimes assumed conversely that a weld which failed is defective if no plug is present. Spot welds do not necessarily form a plug when fractured. Fracture behavior of spot welds both by overload and fatigue is reviewed. Then techniques for examination of field failures are discussed. Finally two case histories are discussed.

The development of injury predictive models for pedestrian thoracic impact based on experimental data obtained in a previous study is presented. The data consists of ten cadaveric test subjects including eight side and two frontal impacts. A ten accelerometer array was mounted on the thorax to define thoracic kinematics. Three types of parameters, Q, B, and PSD, are developed to summarize each acceleration signal. A statistical regression is performed to generate empirical models for predicting the injury level (number of rib fractures) from these parameters. Coefficients of determination for these models range from 0.8 to 0.99 with the new PSD parameter showing exciting promise. Success of these parameters in predicting thoracic injury implies a relationship with frequency, particularly in the neighborhood of 60 Hz.

A test procedure that rates brake performance must control variability so that measured differences between vehicles are real. Tests were conducted using standard brake test procedures with three drivers in three cars on wet and dry asphalt with the ABS working and disabled. The differences between vehicles were greater than differences due to ABS condition, surface condition, and drivers. The procedure measured differences between all the vehicles with statistical certainty but used many replications and drivers. If only large differences in performance need to be distinguished, fewer replications and drivers will be needed.