Materials for Automobile Bodies

Materials for Automobile Bodies, 2nd Edition

Materials for Automobile Bodies, 2nd Edition,Geoffrey Davies,ISBN9780080969794






235 X 191

Comprehensive industry guide to the latest automobile body material options and technologies

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Key Features

  • Up-to-date detailed information on contemporary autobody materials, incorporating the explanation often lacking in other data-focused resources
  • Includes informative and insightful case studies on the materials and processing choices of major OEMs, including Honda, BMW and Audi
  • Now with more on geographical supply and usage trends, environmental concerns and end of life disassembly considerations, and how these affect selection choices


The selection of automobile body materials is fundamental to the choice of fabrication method, and the characteristics and performance of the final vehicle or component. The factors behind these choices comprise some of the key technological and design issues facing automotive engineers today.

Materials for Automobile Bodies brings together a wealth of information on automotive materials and material technologies to provide designers and vehicle body engineers with both a solid grounding and a quick reference to inform their material choices. Coverage includes materials processing, formability, welding and joining, anti-corrosion technologies, plus a comprehensive consideration of the implications of materials selection on these processes.

Dealing with the whole assembly process from raw material to production, right through to recycling at the end of a vehicle's life, this book is the essential resource for practising engineers, designers, analysts and students involved in the design and specification of motor vehicle bodies and components.


Automotive engineers; Design engineers, materials specialists and production supervisors seeking a quick, easy to read reference to inform the automotive material decision process; Graduate students of automotive/ mechanical design and materials science.

Geoffrey Davies

Fellow Institute of Materials MSc University of Oxford

Following 10 years with Richard Thomas and Baldwins Ltd. (now Corus) engaged mainly on research into sheet steel products destined for the automotive industry, a further 35 years was spent on materials technology focused on the car body. This included spells at The Pressed Steel Company, Austin-Morris, BL Technology, Rover and finally BMW UK. Experience included all aspects of material selection raging from sheet steel to aluminium and polymers together with a detailed knowlege of most processing aspects such as pressing, painting and welding. Corrosion prevention was a major feature of recent years and collaborative work with Oxford University helped optimise the use of zinc coated steels on current bodywork.

Affiliations and Expertise

Materials consultant and former head of body materials selection at BMW (UK)

Materials for Automobile Bodies, 2nd Edition


CHAPTER 1. Introduction

1.1 Introduction

1.2 Overview of content

1.3 Materials overview

1.4 General format of presentation

1.5 Introduction to body architecture and terminology


CHAPTER 2. Design and material utilization



2.1 Introduction

2.2 Historical perspective and evolving materials technology

2.3 Finite element analysis

2.4 One manufacturer’s approach to current design

2.5 Panel dent resistance and stiffness testing

2.6 Fatigue

2.7 Alternative body architecture

2.8 Integration of materials into designs

2.9 Engineering requirements for plastic and composite components

2.10 Cost analysis

Learning points


CHAPTER 3. Materials for consideration and use in automotive body structures



3.1 Introduction

3.2 Material candidates and selection criteria

3.3 Steel

3.4 Aluminum

3.5 Magnesium

3.6 Polymers and composites

3.7 Repair

Learning points


CHAPTER 4. The role of demonstration, concept and competition cars



4.1 Introduction

4.2 The ECV 3 and ASVT

4.3 Collaborative development programs

4.4 Concept cars

4.5 Competition cars

4.6 Rally cars

4.7 Hypercars

Learning points


CHAPTER 5. Component manufacture



5.1 Steel formability

5.2 Aluminum formability

5.3 Manufacture of components in magnesium

5.4 Production of polymer parts

Learning points


CHAPTER 6. Component assembly



6.1 Introduction

6.2 Welding

6.3 Adhesive bonding

6.4 Weldbonding

6.5 Mechanical fastening

Learning points


CHAPTER 7. Corrosion and protection of the automotive structure



7.1 Introduction

7.2 Relevant corrosion processes

7.3 Effective design principles

7.4 Materials used for protection of the body structure

7.5 Empirical vehicle and laboratory comparisons

7.6 Introduction to electrochemical methods

Learning points


CHAPTER 8. Environmental and safety considerations



8.1 Introduction

8.2 Effect of body mass and emissions control

8.3 Life-cycle analysis

8.4 Recycling and ELV considerations

8.5 Hygiene

8.6 BIW design for safety

Learning points


CHAPTER 9. Future trends in automotive body materials



9.1 Introduction

9.2 Geographic aspects

9.3 Quantitative assessment

9.4 Factors influencing material change in the future

9.5 Combined effect of factors on materials utilization within ‘expected’ and ‘accelerated’ timescales

Learning points



Quotes and reviews

"Overall…an excellent book.  I would have no hesitation recommending it to those studying automotive engineering or automotive materials, as well as engineers in the early stages of their careers in body engineering, materials and manufacturing roles."--Materials World February 2013, page 52

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