CORUS DEVELOPS UNIQUE INTEGRATED CRASH BOX BUMPER

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CORUS DEVELOPS UNIQUE INTEGRATED CRASH BOX BUMPER
20 April 2006 - Corus

Corus 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.

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. Tube 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 that as well as reducing cost and weight to below the 8kg weight target this unique, lightweight bumper system meets both European and North American pedestrian safety impact targets whilst maintaining performance for absorbing and dissipating forces during head-on collisions."

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

http://www.corusgroup.com

About: Corus
Corus Group Plc is one of the world's largest metal producers with an annual turnover of £8 billion and major operating facilities in the UK, the Netherlands, Germany, France, Norway and Belgium. Corus' four divisions comprising Strip Products, Long Products, Distribution & Building Systems and Aluminium provide innovative solutions to the construction, automotive, packaging, mechanical engineering and other markets worldwide.

Corus has 48,500 employees in over 40 countries and sales offices and service centres worldwide. Combining international expertise with local customer service, the Corus brand represents quality and strength.

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