Steel Bumper Systems for Passenger Cars and Light Trucks

Bumper engineers at the OEMs and Tier One suppliers are faced with the challenge of designing economical and lightweight bumper systems that are compatible with current styling trends. This paper is aimed at helping North American bumper engineers meet the challenge.

There is a wide range of high-strength and ultra high strength bumper steels available. Many of these steels were not in the marketplace as recently as five years ago. These steels are reviewed as well as appropriate manufacturing methods for converting them into bumper facebars and reinforcing beams. Leading edge bumper beam examples are given.

Steel, aluminum and composite reinforcing beams are compared from the weight (mass) point of view. Bumper systems incorporating beams made from these materials are also compared from the manufacturing cost and repair cost points of view.