Development of Lightweight Door Intrusion Beams Utilizing an Ultra High Strength Steel

Door intrusion beams have been fabricated from an ultra high strength steel resulting in an efficient side impact protection system. Despite the ultra high strength (yield strength∼150 ksi) the steel may be roll formed into beams from thin gauge material (0.035 in) resulting in significant vehicle weight savings while still meeting all federal specifications. This paper covers the development of this door intrusion beam system and includes detailed descriptions of beam design, beam testing and steel properties.