What material are car bodies made of? Materials used on the day of manufacture of body parts How to make a car body

Good afternoon, today we will tell you about what the car body is made of, what materials are used in production, as well as with the help, what technologies this important process is underway. In addition, we will find out what exist the main varieties of metals, plastic and others materials, which often used for productionbody elements vehicle, and also consider what are the benefits with disadvantages possesses this or that raw material individually each of the kind... In conclusion, we will talk about what material is by far the most demanded at car manufacturers, and what the quality depends on and durability finished body cars.

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WHAT IS A LARGE ASSEMBLY OF CARS

Body any car plays a role supporting structure, in which it is used for production huge variety various materials and components... To body machines served mine life time reliably, as well as high quality, you need to understand how follow correctly and exploit... To understand this, you need to know what the supporting structure is made of vehicle as well what welding technology and production applied. Thanks to this information, we can easily identify benefits and limitations one or another body type.

Note for reference that for body making need hundreds of individual spare parts, components and details which are then very much needed exactly and also competently connect v single structure, which will be unite everything in itself the elements vehicle. To make durable, wherein safe, light and by acceptable cost body modern car, you need to constantly search various compromises, and new technologies with materials.

1. Manufacturing of a car body from steel. Advantages and disadvantages

Majority bodies the car, or rather its parts are made from different steel grades, aluminum alloys and even plastics with addition fiberglass... But the main the material for today is still low carbon sheet steel with an approximate thick v 0.7-2 mm... Through the use of thin sheet steel, automakers have succeeded reduce overall weight vehicle and at the same time increase body rigidity.

High body strength obtained thanks to special properties and composition of steel as well as his ability to deep hood, that is, you can make details of complex shapes... In addition, we must not forget that new technologies v welding help to get high-tech connections... but steel possesses high density and weak corrosion resistance, therefore, such material requires special additional activities for protection from corrosion.

During body building from become, task constructors is to endow material durability and ensure a high level of passive safety... Task technologists is the right selection of steel composition, his combination with others alloys and components so that the material is good stamp... The task is metallurgists is to correct piss off required by the composition and quality steel... For reference, we note that dozens of new varieties and steel grades, which allow simplify production and also get given specialists properties supporting structure vehicle.

Usually, body making happens in several stages of the production process... Originally occurs making, and then rolling steel sheets that possess different thickness... After that, the sheets are subjected to stamping to create certain parts of the machine kit... At the final stages ready stamped parts welded special method and are going into a single carrier node he is body... Note for reference that almost all welding on car factories produced by special high-precision robots.

Positive aspects of steel at production automotive bodies :

-low cost material in comparing with another raw materials;

- clearly proven manufacturing technologyI am and recycling material;

- optimal maintainability finished body.

Negative sides of steel at production automotive bodies :

- high mass material and finished body;

- need in a special stamping and a lot stamps for fastening details;

-not long service life finished body.

Concerning negative sides in production body from become, then thanks to the constant improvingtechnologiesmaking automotive details, and stamping process, the material becomes the most optimal for car manufacturers. Today, proportion of high-strength steels v body structure constantly increases... Most car manufacturers today use ultra-high strength alloys steel of a new generation.

To such types material include such steel grade, how TWIP which contains a large number of manganese in his the composition, share substances can go up to 25 percent. Steel such type possesses high plasticity, resistant to frequent deformations, thanks to which the material can expose relative lengthening. Elongation"TWIP steel"may happen 50-70 percent, and the limit strength serves index v 1450 MegaPascal... For comparisons, strength of ordinary steel is no more than 250 MegaPascal, a high-strengthup to 600 MegaPascal.

2. Manufacturing of a car body from aluminum. Advantages and disadvantages

As for automobile bodies from aluminum alloys then they became produce more recently, about 15 years ago, for industry this is considered a small period. Usually, aluminum v automotive industry apply for manufacturing of individual body parts, less often whole. In most cases aluminum used for production hoods, wings, doors, To trunk lids as well as other elements and details.

By car manufacturers today aluminum alloys used in limited quantities. All this is due to the fact that rigidity and strength of aluminum alloys much lower than that of the same become... In this connection thickness of parts from this material manufacturers increase therefore significant weight reduction finished body almost impossible to get. Moreover, such parameter, how soundproofing at aluminum parts also worse than steel elements, moreover, for production more complex procedures, to reach optimal acoustic effect and achieve positive body characteristics therefore indicator.

Concerning production process in which make ready aluminum body, then it is very similar to the previously described procedure for creating supporting structure from become... On first stage,details from aluminum sheet subject stamping and then going to one single piece... At welding applied argon, parts connect through dedicated rivets or glue... On the final stage, the main plots the future body subject spot welding and then to steel frame made of pipes miscellaneous cross-sections are attached body panels and car kits.

Positive aspects of aluminum at production automotive bodies :

There is a possibility of production body elements of any shape and difficulties;

- weight finished aluminum body much lighter than steel, at equal strength;

- material easy to process, process recycling simple;

- high sustainability To corrosion and rust;

- low cost of technological processes in production.

Negative sides of aluminum at production automotive bodies :

High complexity of repair details;

- used in production expensive fasteners for panel connections;

- need availability special high-precisionequipment;

- much more expensive than steel, in connection with high energy consumption.

Aluminum possesses middleplasticity and sustainability to different kinds deformations... Such material Not recommended exposelengthening, in connection with thin nominal thickness. The limitstrength of aluminum serves index v 180-210 MegaPascal... For comparisons, strength of standard steel is about 240-250 MegaPascal, a high-strength near 500-600 MegaPascal.

3. Manufacturing of a car body from fiberglass and plastic. Advantages and disadvantages

With regard to production fiberglass bodies, then we mean such material, how fiberfill who specifically impregnated with polymer resins... Typically, this type of material is used for lightening the total mass finished body... The most famous fillers he is fiberglass are fiberglass, kevlar and carbon.

Note for reference that approximately 85 percent plastics that apply in automotive industry, fall on 5 main types of materials , such as polyurethanes, polyvinylchloride, ABS plastic, polypropylene and fiberglass... About 15 percent remaining falls on polyethylene, polyacrylates, polyaforeign ministries, polycarbonates and other materials.

In addition, from different types of fiberglass produce exterior body panels, which in turn provides significant weight loss finished vehicle. For example from polyurethane make pillows and backrests, shockproof pads and others Components... Literally like a couple of years ago from fiberglass started in droves produce such the elementsbody, how hoods, wings, doors and trunk lids.

Positive aspects of fiberglass at production automotive bodies :

Having highstrength, the part has light weight;

- outer surface elements possesses optimal decorative parameters;

- ease of manufacture elements that have complex shape;

There is a possibility of production large parts.

Negative sides of fiberglass at production automotive bodies :

- comparatively high price on fillers;

- high requirements To accuracy of shapes, markup and finished part;

- production of parts carried out continuous time;

High complexity v renovation at damage details.

For reference, note that quite often materials such as polyvinylchloride used for production shaped parts, for example handles, dashboards and other elements. Often polyvinylchloride apply jointly with upholstery materials, using the example of different fabrics... Concerning polypropylene, then it is often made from headlight housings, steering columns, air ducts and other elements. ABS plastic used for cladding parts, how interior and exterior car.

Video review: "What is the car body made of. What materials are used in the production"

In conclusion, note that Automotive industry today is not worth the place and is trying to develop towards the buyer who wants dynamic, economical, reliable, safe and wherein not expensive car. It all leads automotive industry to the fact that in the production of vehicles are used new technologies and materials who answer modern requirements, and standards.

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Throughout history, from the moment the car was created, the search for new materials was constantly conducted. And the car body was no exception. The body was made of wood, steel, aluminum and various types of plastic. But the search did not stop there. And, probably, everyone is curious about what material car bodies are made of now?

Probably, body manufacturing is one of the most difficult processes in the development of a car. The workshop in the plant, where the bodies are made, covers an area of approximately 400,000 square meters, the price of which is billion dollars.

For the production of the body, more than a hundred of individual parts are needed, which then need to be combined into one structure that connects all the parts of a modern car inside itself. For lightness, strength, safety and low cost of the body, designers must always make compromises, find new technologies, new materials.

Let's see the shortcomings and advantages of the main materials used in the manufacture of modern car bodies.

Steel.

This material has been used for the production of bodies for a long time. Steel has excellent characteristics, allowing the production of parts of various shapes, and using different welding methods to connect the necessary parts into a whole structure.

A new grade of steel (hardened during heat treatment, alloyed) has been developed, which makes it possible to simplify the creation and in the future to obtain these characteristics of the body.

The body is made in several steps.

From the very beginning of production, individual parts are stamped from iron sheets of different thicknesses. After that, these parts are welded into large units and are assembled by welding into one whole. Welding in modern factories is carried out by bots, and manual types of welding are also used - semiautomatic in a carbon dioxide environment, or resistance welding is used.

With the advent of aluminum, it became necessary to develop new technologies to obtain these parameters, which should be in iron bodies. The development of Tailored blanks is just one of the novelties - butt-welded iron sheets of various thicknesses from various types of steel form a blank for stamping. Thus, the individual parts of the made part have ductility and strength.

low price,

the highest maintainability of the body,

elaborated development of production and disposal of body parts.

the largest mass,

corrosion protection required,

the need for a large number of dies,

their overhead,

also a limited lifespan.

Everything goes into action.

All materials mentioned above have positive characteristics. Therefore, designers design bodies that combine parts from various materials. When using them, you can bypass the shortcomings, and use only positive properties.

The body of the Mercedes-Benz CL is an example of a hybrid design, because the materials used in the manufacture are aluminum, steel, plastic and magnesium. The bottom of the luggage compartment and the frame of the engine compartment, and some individual frame elements are made of steel. A number of external panels and frame parts are made of aluminum. The door frames are made of magnesium. The trunk lid and front fenders are made of plastic. It is also possible for a body structure in which the frame will be made of aluminum and steel, and the outer panels will be made of plastic and / or aluminum.

the weight of the body is reduced, while maintaining the firmness and strength,

the advantages of each of the materials are used very much when applied.

the need for special technologies for joining parts,

difficult disposal of the body, because it is necessary to disassemble the body into elements earlier.

Aluminum.

Duralumin alloys for the production of auto bodies began to be used relatively recently, although they were used for the first time in the past century, in the 30s.

Aluminum is used in the manufacture of the entire body or its individual parts - the hood, frame, doors, trunk roof.

The initial step in the production of a duralumin body is similar to the creation of an iron body. Parts are first stamped from a sheet of aluminum, and later assembled into a whole structure. Welding is used in argon atmosphere, riveted joints and / or with the use of special glue, laser welding. Also, body panels are attached to the iron frame, which is made of pipes of various cross-sections.

the ability to make parts of any shape,

the body is lighter than iron, while the strength is equal,

ease of processing, recycling is not difficult,

resistance to corrosion (not counting chemical), as well as low cost of technological processes.

low maintainability,

the need for expensive methods of joining parts,

the need for special equipment,

much more expensive than steel, because energy costs are much higher

Thermoplastics.

This is a type of plastic material that, with increasing temperature, runs into a liquid state and becomes fluid. This material is used in the manufacture of bumpers, interior trim parts.

lighter than iron,

low processing costs,

low cost of preparation and production itself when compared with duralumin and iron bodies (no need for stamping parts, welding creation, electroplating and painting production)

the need for huge and expensive injection molding machines,

in case of damage, it is difficult to repair, in some cases the only way out is to replace the part.

Fiberglass.

The name fiberglass means any fibrous filler that is impregnated with polymeric thermosetting resins. The more famous fillers are carbon, fiberglass, kevlar, and also plant fibers.

Carbon, fiberglass from the group of carbon plastics, which are a network of interwoven carbon fibers (moreover, weaving occurs at various specific angles), which are impregnated with special resins.

Kevlar is a synthetic polyamide fiber that is lightweight, resistant to the highest temperature, non-combustible, tensile strength superior to steel a couple of times.

The development of the production of body parts consists in the following: in special matrices, a filler is placed in layers, which is impregnated with a synthetic resin, then left for its polymerization for a certain time.

There are a number of methods for the manufacture of bodies: a monocoque (the whole body is one part), an external plastic panel mounted on a duralumin or iron frame, as well as a body that goes without interruption with load-bearing elements inserted into its structure.

with the highest strength, low weight,

the surface of the parts has good decorative properties (this will allow to get rid of painting),

simplicity in the manufacture of parts with a complex shape,

huge dimensions of body parts.

the highest price of aggregates,

the highest requirement for shape accuracy and cleanliness,

the production time of the parts is quite long,

in case of damage, it is difficult to repair.

6.2. What car bodies are made of

No other element of a passenger car has so many different materials used as in the body. These are structural, finishing, insulating and other types of materials.

The main body parts are made of steel, aluminum alloys, plastics and glass. Moreover, preference is given to low-carbon sheet steel with a thickness of 0.6 ... 2.5 mm. This is due to its high mechanical strength, non-scarcity, ability to deep drawing (parts of complex shape can be obtained), manufacturability of joining parts by welding, etc. The disadvantages of this material are very high density (therefore the bodies are heavy) and low corrosion resistance, requiring complex and costly protection measures.

Aluminum alloys are still used in body construction in limited quantities. Since the strength and stiffness of these alloys is lower than that of body steel, therefore, the thickness of the parts has to be increased and a significant reduction in body weight cannot be obtained. In addition, the soundproofing ability of aluminum parts is lower than that of steel parts, and more complex measures are required to achieve the required acoustic performance of the body. Considering the high thermal conductivity of the material and the formation of aluminum oxides with a high melting point on its surface, it is necessary to use more powerful and expensive equipment for welding aluminum parts.

Nevertheless, examples of the widespread use of aluminum in car bodies are known. Back in the 50s. in France, a Panar-Dina car with an aluminum alloy body was produced, and later a Citroen ZXS-19 car. had an aluminum roof. There is reason to believe that with the improvement of the physical and mechanical properties of aluminum alloys, the solution of technological and other issues, these materials will take a worthy place in the bodywork.

About 80% of plastics used in cars are made up of five types of materials: polyurethanes, polyvinyl chlorides, polypropylene, ABS plastics, and fiberglass. The remaining 20% are polyethylene, polyamides, polyacrylates, polycarbonates, etc.

Exterior body panels are made of fiberglass, which provides a significant reduction in vehicle weight. So, the body of a passenger car "Corvette" model 1984 is 113 kg lighter than a similar steel one.

Polyurethane foam is used to make seat cushions and backrests, shock-resistant linings, etc. A relatively new trend is the use of this material for the manufacture of fenders, hoods, trunk lids, etc.

Polyvinylchlorides are used for the manufacture of many shaped parts (instrument panels, handles, etc.) and upholstery materials (fabrics, mats, etc.). Headlight housings, steering wheels, bulkheads and much more are made of polypropylene. ABS plastics are used for various cladding parts.

The amount of glass in car bodies is steadily increasing. This is due to the desire to improve visibility, to give the car a more aesthetic appearance. Mostly inorganic glasses are used. Their transparency depends on the quality of the surface treatment (unpolished or polished), and their mechanical characteristics depend on the heat treatment (unhardened or hardened). Once hardened, the glass must not be cut or drilled. In the event of an impact, it is crushed into small pieces with blunt edges, which is why such glass is called safe. Tempered glass has a thickness of 3 ... 6 mm.

Safety glasses can be obtained by gluing, for example, two sheets of inorganic thin glass with a transparent film of polymethyl acrylate or full acetate. The result is shatterproof durable glass, called triplex. With a strong impact, such glasses break up into fragments, held on an intermediate layer with a thickness of 0.4 ... 0.8 mm. (Glasses with a thicker interlayer have high bending and impact strength.)

Organic (polymer) glass is highly transparent, easy to paint, and is able to trap infrared rays - (prevent the interior from heating up by the sun's rays). However, they also have a very significant drawback - they are easily scratched. Such glasses are made of polycarbonate or methyl methacrylate.

Throughout history, from the moment the car was created, there has been a constant search for new materials. And the car body was no exception. The body was made of wood, steel, aluminum and various types of plastic. But the search did not stop there. And, for sure, everyone is interested in what material are car bodies made of today?

Perhaps the manufacture of a body is one of the most difficult processes when creating a car. The workshop in the bodywork plant covers an area of approximately 400,000 square meters and is worth a billion dollars.

For the manufacture of a body, more than a hundred separate parts are needed, which then need to be combined into one structure that connects all parts of a modern car. For lightness, strength, safety and minimum cost of a body, designers need to make compromises all the time, look for new technologies, new materials.

Consider the disadvantages and advantages of the main materials used in the manufacture of modern car bodies.

Steel.

This material has been used for the manufacture of bodies for a long time. Steel has good properties, allowing the production of parts of various shapes, and using various welding methods to connect the necessary parts into a whole structure.

A new grade of steel (hardened during heat treatment, alloyed) has been developed, which makes it possible to simplify production and in the future to obtain the specified properties of the body.

The body is made in several stages.

From the very beginning of production, individual parts are stamped from steel sheets of different thicknesses. After that, these parts are welded into large units and are assembled by welding into one whole. Welding in modern factories is carried out by robots, but manual types of welding are also used - semiautomatic in a carbon dioxide environment or resistance welding is used.

With the advent of aluminum, it became necessary to develop new technologies to obtain the desired properties that steel bodies should have. Tailored blanks technology is just one of the novelties - butt-welded steel sheets of various thicknesses from various grades of steel form a blank for stamping. Thus, the individual parts of the manufactured part have ductility and strength.

low cost,

high maintainability of the body,

proven technology for the production and disposal of body parts.

the largest mass

corrosion protection required,

the need for a large number of stamps,

their high cost,

and also a limited lifespan.

Everything goes into action.

All materials mentioned above have positive properties. Therefore, designers design bodies that combine parts from different materials. Thus, when using it, you can bypass the disadvantages, and use exclusively positive qualities.

The body of the Mercedes-Benz CL is an example of a hybrid design, as the materials used are aluminum, steel, plastic and magnesium. The bottom of the luggage compartment and the frame of the engine compartment, and some individual frame elements are made of steel. A number of exterior panels and frame parts are made from aluminum. The door frames are made of magnesium. The trunk lid and front fenders are made of plastic. It is also possible to have a body structure in which the frame is made of aluminum and steel, and the outer panels are made of plastic and / or aluminum.

the weight of the body is reduced, while the rigidity and strength are preserved,

the advantages of each of the materials are used to the maximum during application.

the need for special technologies for joining parts,

complex disposal of the body, since it is necessary to first disassemble the body into elements.

Aluminum.

Aluminum alloys for the manufacture of car bodies began to be used relatively recently, although they were used for the first time in the last century, in the 30s.

Aluminum is used in the manufacture of the entire body or its individual parts - the hood, frame, doors, trunk roof.

The initial stage of manufacturing an aluminum body is similar to manufacturing a steel body. Parts are first stamped from a sheet of aluminum, then assembled into a whole structure. Welding is used in argon atmosphere, riveted joints and / or using special glue, laser welding. Also, body panels are attached to the steel frame, which is made of pipes of different cross-sections.

the ability to make parts of any shape,

the body is lighter than steel, while the strength is equal,

ease of processing, recycling is not difficult,

corrosion resistance (except electrochemical), as well as low cost of technological processes.

low maintainability,

the need for expensive methods of joining parts,

the need for special equipment,

much more expensive than steel, since energy costs are much higher

Thermoplastics.

This is a type of plastic material that, when the temperature rises, becomes liquid and becomes fluid. This material is used in the manufacture of bumpers, interior trim parts.

lighter than steel,

minimum processing costs,

low cost of preparation and production itself when compared with aluminum and steel bodies (no need for stamping of parts, welding production, electroplating and painting production)

the need for large and expensive injection molding machines,

in case of damage, it is difficult to repair, in some cases the only way out is to replace the part.

Fiberglass.

The name fiberglass is any fibrous filler that is impregnated with polymeric thermosetting resins. The most famous fillers are considered - carbon, fiberglass, kevlar, as well as fibers of plant origin.

Carbon, fiberglass from the group of carbon plastics, which are a network of interwoven carbon fibers (moreover, weaving occurs at different specific angles), which are impregnated with special resins.

Kevlar is a synthetic polyamide fiber that is lightweight, resistant to high temperatures, non-combustible, tensile strength exceeding steel several times.

The technology for the manufacture of body parts is as follows: a filler is placed in special matrices in layers, which is impregnated with a synthetic resin, then left to polymerize for a certain time.

There are several ways to manufacture bodies: a monocoque (the whole body is one piece), an outer plastic panel mounted on an aluminum or steel frame, as well as a body that runs without interruptions with load-bearing elements integrated into its structure.

low weight with high strength,

the surface of the parts has good decorative qualities (this will allow you to refuse painting),

simplicity in the manufacture of parts with a complex shape,

large sizes of body parts.

high cost of fillers,

high requirements for accuracy of shapes and cleanliness,

the manufacturing time of the parts is quite long,

in case of damage, it is difficult to repair.

Consider the disadvantages and advantages of the main materials used in the manufacture of modern car bodies.

Steel.

A new grade of steel (hardened during heat treatment, alloyed) has been developed, which makes it possible to simplify production and in the future to obtain the specified properties of the body.

The body is made in several stages.

With the advent of aluminum, it became necessary to develop new technologies to obtain the desired properties that steel bodies should have.

Tailored blanks technology is just one of the new products. Butt-welded steel sheets of various thicknesses from various grades of steel form a blank for stamping. Thus, the individual parts of the manufactured part have ductility and strength.

low cost,

high maintainability of the body,

proven technology for the production and disposal of body parts.

the largest mass

corrosion protection required,

the need for a large number of stamps,

their high cost,

as well as limited service life.

Everything goes into action.

The body of the Mercedes-Benz CL is an example of a hybrid design, as the materials used are aluminum, steel, plastic and magnesium. The bottom of the luggage compartment and the frame of the engine compartment, and some individual frame elements are made of steel. A number of exterior panels and frame parts are made of aluminum. The door frames are made of magnesium. The trunk lid and front fenders are made of plastic. It is also possible to have a body structure in which the frame is made of aluminum and steel, and the outer panels are made of plastic and / or aluminum.

the weight of the body is reduced, while the rigidity and strength are preserved,

the advantages of each of the materials are used to the maximum during application.

the need for special technologies for joining parts,

complex disposal of the body, since it is necessary to first disassemble the body into elements.

Aluminum.

Aluminum alloys for the manufacture of car bodies began to be used relatively recently, although they were used for the first time in the last century, in the 30s.

Aluminum is used in the manufacture of the entire body or its individual parts, the hood, frame, doors, trunk roof.

the ability to make parts of any shape,

the body is lighter than steel, while the strength is equal,

ease of processing, recycling is not difficult,

resistance to corrosion (except electrochemical), as well as low cost of technological processes.

low maintainability,

the need for expensive methods of joining parts,

the need for special equipment,

much more expensive than steel, since energy costs are much higher

Thermoplastics.

This is a type of plastic material that, when the temperature rises, becomes liquid and becomes fluid. This material is used in the manufacture of bumpers, interior trim parts.

lighter than steel,

minimum processing costs,

low cost of preparation and production itself when compared with aluminum and steel bodies (no need for stamping of parts, welding production, electroplating and painting production)

the need for large and expensive injection molding machines,

in case of damage, it is difficult to repair, in some cases the only way out is to replace the part.

Fiberglass.

The name fiberglass is any fibrous filler that is impregnated with polymeric thermosetting resins. The most famous fillers are carbon, fiberglass, kevlar, as well as plant fibers.

Kevlar is a synthetic polyamide fiber that is lightweight, resistant to high temperatures, non-flammable, tensile strength exceeding steel several times.

There are several ways to manufacture bodies: a monocoque (the whole body is one piece), an outer plastic panel mounted on an aluminum or steel frame, as well as a body that goes without interruption with power elements integrated into its structure.

low weight with high strength,

the surface of the parts has good decorative qualities (this will allow you to refuse painting),

simplicity in the manufacture of parts with a complex shape,

large sizes of body parts.

high cost of fillers,

high requirements for accuracy of shapes and cleanliness,

the manufacturing time of the parts is quite long,

in case of damage, it is difficult to repair.

No one doubts that the load-bearing body of the car body is the main and most difficult part of a modern vehicle in production (and therefore in price). He will be discussed in this article.

From the history.

Of course, in the era of carts and carriages (the beginning of the history of bodies), he saved people from changeable weather, and served as a container for goods. With the inception of the automotive industry, devices and assemblies were "disguised" under the external body panels. For a long time, the body worked patiently only as a roof protecting cargo, passengers, and devices. For the first time, in half a century of the XX century, measures were launched to remove the bearing function from the frame, and transfer this component to the body. After development, which lasted several years, the body became "load-bearing". In other words, in addition to personal "innate" functions, the body began to play the role of a support frame for vehicles, suspension, etc.

In order to achieve suitable stability, torsional and bending rigidity, frame fragments were introduced into the body system: spars and cross members, along the way, the roof with its pillars, doors, and so on were reinforced. The ancestor of frameless serial machines was the domestic "Victory", the creation of which started in 1945. Of course, at the very beginning of production, load-bearing bodies were inferior in strength to frame systems.

For this period, the situation has changed towards the former. In any case, the difference is quite insignificant. In open-top cars, the lack of rigidity was compensated for by reinforcing the bottom of the car. In some designs, rigidity was achieved by connecting the side members of the front and rear parts, a structure that was more resistant to impacts.

A little about definitions.

Body geometry the location of the front and rear suspension, gearbox devices, doors, windows and gaps strictly defined by the body system.

Changes (accidents, modernization) of the body geometry lead to changes in movement, uneven wear of rubber and worsens the safety of passengers (increasing the possibility of skidding, opening doors on the move, etc.).

Crumple zones body design-specific seats with reduced rigidity, specially designed to absorb impact energy. Crumple zones are provided to preserve the integrity of the car interior and the health of passengers.

Contact welding the method of electric welding, where electrodes are supplied to the areas of the parts to be welded, and a current of increased power is carried out. In the heating position, the alloy of the elements melts, forming a homogeneous joint. Welding spots are continuous and spot. The second method is called "spot welding" (the connection is made at a distance of about 5 cm from the neighboring point).

Laser welding connection of elements using a focused laser beam. The temperature at the junction is simply enormous, but the distance of the melt from the edges is very small. Hence, a huge plus of this method appears, an almost invisible welding place. This means that there is no need to process the weld seam.

Power frame the bottom, pillars, roof with window frames, spars, beams-amplifiers and other power components welded into a common structure, forming as a whole a "cocoon" in which the passenger car compartment is located.

Bodyguard body.

In the modern high-speed world, the load-bearing body of the car body has begun to fulfill a new task, the second level of passenger protection. On the first - belts, airbags, etc. For this, the car body was divided into zones with different degrees of rigidity. The front and rear were made more "pliable", successfully absorbing the power of the impact, and the body of the cabin was made more rigid in order to eliminate the occurrence of traumatic situations and the pressing of the units into the interior of the body. Energy absorption is maintained by crumpling some of the load-bearing structures, which can harm the health of passengers.

An unconventional solution was made in passive protection and increased body rigidity by Mercedes class A designers. In order for the engine under the short hood to not harm passengers in an accident, the bottom itself was designed by the designers to double form a kind of "sandwich" with a void gap. Of course, with such an assembly, the engine, actually placed at the very bottom, is pressed into this gap in the event of a frontal impact, thereby protecting the passengers of the cabin from damage. Also, it is worth noting the fact that in this interval the battery, gas tank, as well as other units and components of the car are freely located.

What and how are supporting bodies made of.

In the manufacture of bodies, sheet metal is used, which has a different set of parameters. For example, in places where the power loads are increased, a 2.5 mm sheet of metal is used, and 0.8-1.0 mm for the elements of the "plumage" of the hood, fenders, doors, trunk.

All parts from which the body will subsequently appear are connected using several types of electric welding. By the way, some companies use unusual methods of joining body elements, for example, they use laser welding, or they rivet with rivets in combination with very strong glue. In the range of materials for the manufacture of load-bearing bodies, the choice is not great.

Until that time, only sheet metal and, occasionally, aluminum were used in serial cars. In the 80s, in order to protect the body from rust, they began to use galvanized iron for the first period with a single layer of zinc coating, later they began to cover on both sides. As a result, the guarantees against perforating rust on the body have increased from 6 to 10 years, somewhere even up to 12!

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