Corus develops unique integrated crash box bumper

Tata Steel

Corus, one of the world's leading steel producers, has developed an integrated crash box bumper that it believes will offer vehicle and component manufactures both weight and cost savings compared to existing front end module systems.

  • Crash box system offers 20% weight savings with equivalent performance
  • Crash box system offers manufacturing cost savings of up to 10% per unit

Developed by the Corus Hyfo business, based in IJmuiden, in the Netherlands, with the technical support of Corus' RD&T and Corus Automotive Engineering, the unique integrated crash box bumper system is the first of its kind in Europe to market.

It combines the latest hydroform tube technology with advanced high strength dual-phase steels resulting in a monopiece construction that, Corus believes, will contribute to reduced vehicle weight and therefore lower fuel consumption and CO2 emissions.

Crash Box SystemTube hydroforming is one of the new enabling technologies that has the capacity to deliver cost effective mass reduced solutions and is increasingly being used by vehicle manufacturers.

In addition to offering lighter component solutions, tube hydroforming can also help deliver manufacturing cost reductions through the use of fewer components.

As such, Corus believes that the unique monopiece crash box bumper system will reduce manufacturing costs by up to ten per cent per unit.

Corus employed its unique materials analysis simulation technique called Forming to Crash or F2C® to further optimise the design of the crash box. The hydroforming process can change material strength and thicknesses, both of which can have an influence on component crash performance. F2C® helped Corus engineers to factor in these changes in to a computer crash analysis as part of the development process.

Commenting on developing Corus' integrated crash box bumper, Dr Iain McGregor, Manager Technology, Corus Automotive Engineering said: "Following extensive desktop trials, we have been able to demonstrate reduced cost and weight to below the 8kg weight target, whilst maintaining performance for absorbing and dissipating forces during head-on collisions."

Maarten Kelder, Business Development Manager, Corus Hyfoconcludes: "We look forward to working with vehicle manufacturers to take the system forward to future new vehicle platforms."

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