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Advanced High-Strength Steel Guidelines
Brief Overview of A/SP AHSS Application Guidelines Project Overview
The Auto/Steel Advanced High-Strength Application Guidelines Project is compiling detailed case studies on the development and implementation of sheet metal stamping processes that employ AHSS steel grades. The intent of these case studies is to provide AHSS part designers with direction on how to design parts for maximum manufacturability, and to provide AHSS stamping process developers with direction on how to best design die processes for these grades. While there are currently on-going A/SP projects seeking to develop best practices for stamping a variety of AHSS components, these projects will not be complete for some time. This project draws from existing AHSS stamping experience to compile insights that can be used by automotive industry engineers today.

The AHSS Application case studies below can be downloaded for additional study of how other stamping process engineers met and solved the challenges of forming these important new steel grades.
Advanced High-Strength Steel Applications Design and Stamping Process Guidelines - A Special Edition of In-Depth Advanced High-Strength Steel Case Studies (78MB)
Description: The AHSS Applications Guidelines Group of the Auto/Steel Partnership (A/SP) has conducted several in-depth case studies of Advanced High-Strength Steel (AHSS) stampings for automotive structural components and has provided summaries of those studies and lessons learned in this manual.
Reinforcement Center Pillar Outer
Date: January 2007
Description: 2.0 mm gauge HDGI DP590 center body pillar outer reinforcement made by draw forming on a B-class tri-axis transfer press with lower press air cushion.
Reinforcement - Baffle Rocker - R&L
Date: January 2010
Description: 2.0 mm HDGI DP800 Reinforcement - Baffle Rocker - R&L made as a double attached stamping in an 800 ton press with manual transfer between stations.
Panel - Back Inside Side - R&L
Date: January 2010
Description: 1.50 mm gauge HDGI DP600 Panel - Back Inside Side - R&L made as a double attached stamping in a double action toggle draw die at station 1 and straight side mechanical presses at stations 2 through 5.
Reinforcement Center Body Pillar
Date: January 2007
Description: 1.65 mm gauge HDGI DP600 center body pillar reinforcement made by stretch drawing on a 3000 ton, 6-station transfer press.
Reinforcement A-Pillar Rear Upper
Date: January 2007
Description: 1.70 mm gauge HDGA DP600 rear upper A-pillar reinforcement made double attached by draw forming on a six station press line with nitrogen cushion in the draw die. Mating part to that in Case Study 02-02-AHSSAG-GADP600-Reinf A-Plr Frt Upr-Final below.
Plate-Underbody Side Rail
Date: January 2007
Description: 1.50 mm gauge HDGI DP800 rear side rail plate made double attached by draw forming on a double action lead draw C-class tri-axis six-station transfer press.
A-Pillar Front Upper
Date: January 2007
Description: 1.70 mm gauge HDGA DP600 front upper A-pillar reinforcement made double attached by draw forming on a six station press line with die-applied cushion pressure in the draw die. Mating part to that in Case Study 01-03-AHSSAG-GADP600-Reinf A-Plr Rr Upr-Final above.
Reinforcement Center Pillar Outer Upper
Date: October 2007
Description: 1.50 mm CR DP980 center pillar outer upper reinforcement made double attached on a 5500 mm, 2000 ton high speed progressive die press.
Panel Rear Rail
Date: October 2007
Description: 1.95 mm HDGA DP600 rear rail made by toggle draw with delay pad on a five station transfer press line with 2000 ton hydraulic press at station 1 and 1000 ton mechanical presses at stations 2 through 5.
Reinforcement Mid-Rail Upper (Right/Left)
Date: July 2008
Description: 1.20 mm HDGA DP780 mid rail reinforcement made in a 5500 mm long, 2000 ton high speed progressive die press.
Reinforcement A-Pillar Rear Upper
Date: October 2008
Description: 2.0mm HDGA DP600 / HSLA350 Tailor Welded Blank A-pillar upper reinforcement made in a nitro cushion draw die and a 2000 ton hydraulic press followed by line dies in 1000 ton mechanical presses at stations 2 through 5.
Member Floor Side Inner
Date: October 2008
Description: 1.8 mm Hot Dipped 60G60G Dual Phase 600 Floor Side Inner Member (Rocker Panel Inner) that is drawn in an 1800 ton double action press followed by tandem line with a total of four die operations. A developed blank is used for the draw die. Part shape modifications for successful draw operation are illustrated.
2007 GDIS AHSS AG Presentation
Date: January 2007
Description: Overview of the A/SP AHSS Applications Guidelines project. Contains material presented at GDIS 2007 in Livonia, Michigan.
Body Systems Analysis
A Benchmark Study of Automotive Door Dimensional Quality - Executive Summary
Date: January 2002
Committee: Body Systems Analysis Project Team 
Event-Based Functional Build: An Integrated Approach to Body Development - Executive Report
Date: Summer 1999
Committee: Body Systems Analysis Project Team 
Event-Based Functional Build: An Integrated Approach to Body Development - Complete Version
Date: Summer 1999
Committee: Body Systems Analysis Project Team 
Automotive Sheet Steel Stamping Process Variation
Date: Summer 1999
Committee: Body Systems Analysis Project Team 
Automotive Body Measurement System Capability
Date: Summer 1999
Committee: Body Systems Analysis Project Team 
Corrosion
A Guide to Corrosion Protection
Date: December 1999
Committee: Light Truck Frame Project Team 
Description: An analysis of corrosion-related issues for passenger car and light truck underbody structural components
Design Manual
Automotive Steel Design Manual
Date: Revision 6.1 August 2002
Committee: American Iron and Steel Institute - Auto/Steel Partnership 
Description: Reference System
Enhanced Forming Limit Diagrams
Technology Report
Date: January 2003
Committee: Enhanced Forming Limit Diagram Project Team 
Bead Wrap Videos
Date: December 2002
Committee: Enhanced Forming Limit Diagram Project Team 
Database
Date: December 2002
Committee: Enhanced Forming Limit Diagram Project Team 
Training Manual
Date: December 2002
Committee: Enhanced Forming Limit Diagram Project Team 
Research Report (complete)
Date: October 2002
Committee: Enhanced Forming Limit Diagram Project Team 
Description: This 14.6 MB file contains the Research Report and all Appendices (recommended for high speed connections)
Research Report (body only)
Date: October 2002
Committee: Enhanced Forming Limit Diagram Project Team 
Description: This 1.12 MB file contains the body of the report and does not include the Appendices
Research Report Appendices (except Appendix 3.3)
Date: October 2002
Committee: Enhanced Forming Limit Diagram Project Team 
Description: This 1.86 MB file contains all appendices for the Research Report except Appendix 3.3
Research Report Appendix 3.3
Date: October 2002
Committee: Enhanced Forming Limit Diagram Project Team 
Description: This file is 11.7 MB
Future Generation Passenger Compartment
Mass Efficient Architecture for Roof Strength (MEARS)
Date: February 2010
Committee: FGPC Committee 
Description: This project developed mass efficient design solutions using existing Advanced High-Strength Steel (AHSS) applications, various forming technologies, and reinforcements to improve the roof strength performance.
Future Generation Passenger Compartment – Final Report (60MB)
Date: June 2007
Committee: FGPC Committee 
Description: This engineering report presents the findings of a mass reduction study of a donor vehicle passenger compartment design while improving performance to address IIHS Side Impact Crash Event and the proposed FMVSS 2.5X Roof Strength requirements. The study concludes that with rigorous use of Advanced High-Strength Steel and efficient optimized design mass savings of 31.4 percent relative to 2004 baseline vehicles is possible.
Mass Compounding Final Report
Date: June 2007
Committee: FGPC Committee 
Description: This report defines and quantifies the mass compounding effect during vehicle design with current mass influence coefficients developed from mass data of 35 contemporary vehicles. Mass compounding considers that a mass increase in a component has a ripple effect throughout the vehicle; other components need to be resized increasing vehicle mass even more. A more encouraging view of this behavior is considering a reduction in a component mass resulting in a greater mass saving.
Mass Compounding Calculator
Date: June 2007
Committee: FGPC Committee 
Description: This Excel Spreadsheet implements the findings of the mass compounding study into a tool for estimating initial vehicle mass based on conventional vehicle baselines and calculating the additional mass savings possible from an initial mass reduction of a vehicle system(s) or component(s).
High Strength Steel Awareness Bulletins
18) ULSAB: A Lightweight, Affordable, Structurally Superior Steel Auto Body.
Date: Spring 1998
Committee: High Strength Steel Task Force 
17) Ultra High Strength Steel Becoming a Key Material in Critical Safety Components
Date: Fall 1997
Committee: High Strength Steel Task Force 
16) Auto/Steel Partnership Industry Resource Groups Tackle Unique High Strength Steel Challenges.
Date: Winter 1996
Committee: High Strength Steel Task Force 
15) Chrysler Finds Rephosphorized Ultra Low Carbon Steel Improves Dent Resistance While Reducing Weight.
Date: Summer 1996
Committee: High Strength Steel Task Force 
14) High Strength Steel Provides the Support for Chrysler JA Car Underbody.
Date: Spring 1996
Committee: High Strength Steel Task Force 
13) Tailored Blanks Offer Weight and Cost Reductions with Performance Improvements.
Date: Winter 1995
Committee: High Strength Steel Task Force 
12) UltraLight Steel Auto Body Demonstrates Value of Steel in the Automobile's Future.
Date: Fall 1995
Committee: High Strength Steel Task Force 
11) High Strength Steel Usage Reaches New Heights on the Wings of Ford Windstar.
Date: Spring 1995
Committee: High Strength Steel Task Force 
10) The Right Time for the Right Material.
Date: Fall 1994
Committee: High Strength Steel Task Force 
9) Case in Point: A Comprehensive Look at Door Beams and General Motors Puts Its Stamp of Approval on New Side-Impact Beams Stamped of High Strength Steel.
Date: Summer 1994
Committee: High Strength Steel Task Force 
8) Case in Point: High Strength Steel Lights the way for New Chrysler Neon
Date: Spring 1994
Committee: High Strength Steel Task Force 
7) For Steelmakers, The Future is… LIGHT
Date: Winter 1993
Committee: High Strength Steel Task Force 
6) A Second Generation Built of High Strength Steel. Taurus/Sable Hood.
Date: Spring 1993
Committee: High Strength Steel Task Force 
5) Case in Point: The Development of The Roll-Formed High Strength Steel Bumper Support Beam Assembly For The 1992 General Motors N-Cars
Date: Winter 1992
Committee: High Strength Steel Task Force 
4) Case in Point: The Development of the 1993 LH Rear Rail - A Case Study by Chrysler Corporation
Date: Fall 1992
Committee: High Strength Steel Task Force 
3) High Strength Steel Highlights: The Use of High Strength Steels for Automotive Panels. A Discussion on Interviews with Peter Mould, Jay Montgomery, Pete Mooney, Tom Seel – U.S. Steel Group, and Don Allen – Phoenix Consulting, Inc.
Date: Summer 1992
Committee: High Strength Steel Task Force 
2) High Strength Steel Highlights: Case Study of the Ford Taurus Hood
Date: Winter 1991
Committee: High Strength Steel Task Force 
1) Auto/Steel Partnership Introduces New Source for Data on High Strength Steel
Date: Fall 1991
Committee: High Strength Steel Task Force 
Hydroforming Materials and Lubricants
Final Summary Report
Date: March 2004
Committee: Hydroforming Materials and Lubricants 
Joining Technologies
Joint Efficiency Phase II - Executive Summary
Date: October 2009
Committee: Joining Technologies Team 
Description: To study the effects of joining processes on AHSS, tensile test data was generated to calculate joint efficiency, energy, and stiffness for a range of steels. Joining processes included are resistance spot welding, gas metal arc welding, gas metal arc brazing, laser welding, laser brazing, laser hybrid welding, structural monobolting, self pierce riveting, structural adhesive bonding, and weld bonding. Steels included are 1.2 mm Mild, 1.2 mm HSLA, 1.2 mm DP600, 1.0 mm DP780, and 1.0 mm M190. The results of this comparative study provide a baseline reference for a wide variety of welding and joining processes.
GMAW Weld Design Guidelines for Chassis Structures
Date: July 2008
Committee: Joining Technologies Team 
Description: Existing OEM arc welding design standards were compared and evaluated to identify design rules that are applicable to chassis related A/SP Lightweighting Projects
Weld Schedule
Date: September 2008
Committee: Joining Technologies Team 
Description: A/SP Starting Resistance Spot Weld Schedules for AHSS (hyperlink with the attached) The purpose of this Auto/Steel Partnership Joining Technologies project was to determine whether existing AC and DC weld schedules were suitable for advanced high-strength steels (AHSS) classified as IISI Group 3 and 4 materials. Verification of the weld schedules for Group 3 and 4 steels was accomplished by finite element modeling via SORPAS Version 7.0 software and limited welding of 2T and 3T stack-ups to validate the SORPAS results.
Weld Schedule PowerPoint
Date: September 2008
Committee: Joining Technologies Team 
Description: PowerPoint presentation to the 5th International Seminar on Advances in Resistance Welding (ARW) in Toronto on September 24 – 26, 2008 “Development of Starting Weld Schedules for AHSS SORPAS Modeling of Starting Point Weld Schedules with Experimental Evaluation and Validation”.
Weld Bond Adhesive Guidelines
Date: September 2008
Committee: Joining Technologies Team 
Description: This Weld Bond Guideline is intended to provide design information for A/SP projects. It provides information for body structure design engineers and for modeling engineers working on body-in-white designs utilizing adhesives. This information pertains to pumpable adhesives and is applicable for NVH, durability or crash analyses. For more information regarding OEM requirements, please see individual OEM engineering specifications.
A/SP Starting Resistance Spot Weld Schedules for AHSS
Description: A/SP Starting Resistance Spot Weld Schedules for AHSS (hyperlink with the attached) The purpose of this Auto/Steel Partnership Joining Technologies project was to determine whether existing AC and DC weld schedules were suitable for advanced high-strength steels (AHSS) classified as IISI Group 3 and 4 materials. Verification of the weld schedules for Group 3 and 4 steels was accomplished by finite element modeling via SORPAS Version 7.0 software and limited welding of 2T and 3T stack-ups to validate the SORPAS results.
AWS/SAE D8.9M Recommended Practices for Test Methods for Evaluating the Resistance Spot Welding Behavior of Automotive Sheet Steel Materials
Date: March 1, 2008
Committee: AHSS Joining Technologies 
Weld Lobe Development and Assessment of Weldability of Common Automotive Fastners (Studs and Nuts) using Drawn Arc Welding Process
Description: A project to Assess Weldability and Develop Weld Lobes for Common Automotive Studs and Nuts Welded to Advanced High Strength Steels by Utilizing the Drawn Arc Welding Process
An Investigation of Resistance Welding Performance of AHSS
Date: March 2007
Committee: Joining Technologies Team 
Advanced High-Strength Steel (AHSS) Weld Performance Study for Autobody Structural Components
Date: March 2007
Committee: Joining Technologies Team 
Assessing Weldability of Projection Welding Fasteners to AHSS using Finite Element Analysis
Date: March 2007
Committee: Joining Technologies Team 
Temperature Effect on Impact Performance of AHSS Welds
Date: March 2007
Committee: Joining Technologies Team 
Operating Procedures for Conducting the A/SP DOE of Coated Steels
Date: July 30, 1999
Committee: Welding Task Force 
High Strength Steel Weldability DOE Test Method Correlation
Date: December 2, 1998
Committee: Welding Task Force 
Description: Test method correlation study to compare the A/SP weld quality endurance test method top current automotive resistance welding test procedures.
Resistance Spot Welding Electrode Wear On Galvannealed Steels
Date: September 1997
Committee: Electrode Wear Mechanisms Task Force 
Finite Element Modelling Of Electrode Wear Mechanisms
Date: April 10, 1995
Committee: Electrode Wear Mechanisms Task Force 
Mechanisms Of Electrode Wear During Resistance Spot Welding Hot-Dipped Galvanized Steel
Date: June 1994
Committee: Electrode Wear Mechanisms Task Force 
Lightweight Chassis Structures
HYPERVIEWER - Download Required for presentation
ASP 601 Lightweight Rear Chassis Project: As-built Models and Development of Fatigue Analysis Methodology
Date: February 24, 2009
Committee: Lightweight Chassis Structures Team 
Description: This report documents the CAD and FE models of the Phase 1 prototypes and an analytical method for determining the fatigue life of a chassis structure.
Joint Stiffness Toolbox: An Excel Spreadsheet for Predicting Joint Stiffness
Date: October 2005
Committee: Light Truck Frame Project Team 
Light Truck Frame Joint Stiffness Study - Phase 3
Date: January 2005
Committee: Light Truck Frame Project Team 
Light Truck Frame Joint Stiffness Study - Phase 2
Date: Summer 2004
Committee: Light Truck Frame Project Team 
Lightweight SUV Frame Design Development
Date: July 2003
Committee: Light SUV Frame Project Team 
Light Truck Frame Joint Stiffness Study - Phase 1
Date: Summer 2001
Committee: Light Truck Frame Project Team 
Lightweight Closures
Lightweight Closures 2004 Full Report
Date: 2004
Lightweight Closures 2002 Full Report
Date: 2002
Lightweight Closures 2001 Full Report
Date: 2001
Lightweight Front End Structures
Milestone 8 Animation
Date: October 2005
Milestone 7 Animation
Date: October 2005
Milestone 10 Animation
Date: October 2005
Milestone 16 Animation
Date: October 2005
Milestone 22 Animation
Date: October 2005
Proteus Application
Date: October 2005
Lightweight Front End Structures - Final Report (111MB)
Date: October 2005
Milestone 1 Animation
Date: October 2005
Milestone 5 Animation
Date: October 2005
Milestone 6 Animation
Date: October 2005
Material Uniformity
Material Uniformity of High Strength Sheet Steels — Vol. 2
Date: November 1, 1998
Committee: Materials Uniformity Project Team 
A Report On Uniformity Of Coating Weights On Automotive Sheet Steels Volume 2
Date: August, 1995
Committee: Materials Uniformity Project Team 
A Report on Uniformity Of Surface Texture Of Steel Sheet For Automotive Applications
Date: January 1993
Committee: Materials Uniformity Project Team 
Uniformity of Automotive Sheet Steel Properties - Volume 2
Date: March 1991
Committee: Task Force on Uniformity of Materials Properties 
NAAMS Global Standard Components
NAAMS Global Standard Components - Assembly
NAAMS Global Standard Components - Stamping
Sheet Steel Fatigue
A/SP Spot Weld Fatigue Knowledge Base
Date: February 2006
Committee: Sheet Steel Fatigue Project 
Sheet Steel Fatigue Data
Date: April 2004
Committee: Sheet Steel Fatigue Project 
Stamping And Formability
Cross Cowl Executive Summary
Date: June 2007
Committee: AHSS Stamping Committee 
Description: Summary of the springback phenomena associated with a cross cowl structural member made from dual phase steel in stamping tryouts using the A/SP master die shoe.
Cross Cowl Member Stamping Trials - Final Report
Date: June 2007
Committee: AHSS Stamping Committee 
Description: A technical report of the springback phenomena associated with a cross cowl structural member made from dual phase steel in stamping tryouts using the A/SP master die shoe.
High Strength Steel Stamping Design Manual
Date: December 2000
Description: Collaborative product-process development guidelines for high strength steel stampings
Automotive Design Guidelines for Steel Stampings: Design for Manufacturability
Date: January, 1993
Committee: Design Guidelines Subcommittee 
Managing The Stamping Process
Date: October 1991
Committee: Stamping Task Force 
Tailor Welded Blanks
Tailor Welded Blank Applications And Manufacturing - A State of The Art Survey
Date: June 2001
Committee: Tailor Welded Blank Project Team 
The Identification and Analysis of Intangible Benefits of Tailor Welded Blank Applications
Date: Summer 1999
Committee: Tailor Welded Blank Project Team 
Tailor Welded Blank Acceptance Guidelines
Date: July 1995
Committee: Tailor Welded Blank Project Team 
Tailor Welded Blank Checklists
Date: July 1995
Committee: Tailor Welded Blank Project Team 
Tailor Welded Blank Design and Manufacturing Manual
Date: July 1995
Committee: Tailor Welded Blank Project Team 
Description: Although tailor welded blanks were first developed as a way of using collectible offal, the biggest potential today is in the use of tailor welded blanks made of sheet steels with different thicknesses, coatings and properties. Currently, tailor welded blanks are used for bodyside frames, door inner panels, motor compartment rails, center pillar inner panels and wheelhouse/shock tower panels.
Tribology
A/SP Procedures For Testing Characteristics of Automotive Sheet Steel Lubricants
Description: The purpose of this document is to specify the acceptable performance requirements for an automotive sheet metal lubricant. Lubricants include mill oils, prelubes, draw compounds, blankwashes, and dry films. The term "lubricant" used in these procedures is used to describe any product added to the sheet metal that serve the primary purposes of rust prevention, friction reduction, or sheet steel cleanliness.