Structural Strength for Safety
Under Ford’s safety strategy, high-strength steels are used in areas of the vehicle where structural strength and reinforcement are essential for crashworthiness. This includes the floor structure, front rails and beams and new Fiesta’s ultra-rigid, integrated bodyside reinforcement ring to protect against side impact.
High strength materials were used to create a very stiff B-pillar section and stiff rocker section fore and aft. Impact loads are also transferred laterally to the opposite side of the car via chassis cross-members, to maximise dissipation of side impact forces.
This integrated bodyside reinforcement ring resists side intrusion in the unlikely event of a collision and helps the body structure manage the energy of other impacts effectively – be they frontal, offset or rear.
“Some people believe that just counting the number of airbags can gauge safety performance,” says Joerg Beyer, Chief Carline Engineer for new Fiesta. “At Ford, we count first on creating a very strong body structure to protect all occupants. With this robust structure as the first point of defence, we can then optimise our Intelligent Protection System to provide a tailored, protective response.”
To create the bodyside reinforcement ring, high-strength-steel elements were welded into an ultra-stiff structure whose crash performance was carefully developed using advanced computer simulation technology, long before its first real crash tests.
Elements of the bodyside reinforcement ring include:
■ A-Pillar – New Fiesta’s slim A-pillar forms the forward part of the vehicle’s stylish roof arch. It is fashioned from ultra-high-strength aluminised Boron steel. The A-pillar delivers the strength and rigidity required for crashworthiness while remaining fashionably slim, as a key element in Fiesta’s dynamic design, and to minimise its potential to obscure driver visibility
■ B-Pillar – Another Boron steel component, the Fiesta B-pillar reinforcement is shaped for ultra-high strength. Its job is to resist intrusion and retain its structural rigidity in the case of side impacts, while providing the strength to help the vehicle safety cell retain its shape in other crash modes
■ Rocker Panels – New Fiesta’s rocker panels, the lower rails to which the B-pillar is fixed, are crafted from very-high-strength, dual-phase steels renowned for their energy absorption properties
■ Rocker Baffles – To optimise the side-impact performance of the vehicle, uniquely shaped, twin-shear baffles are welded to the inner rocker panel. These stabilise the rocker section to ensure that it performs optimally in the event of a side impact. This is designed to make the rocker panel and B-pillar act as a system, with the B-pillar retaining its shape and its connectivity to the rocker panel in a side impact
■ Side Roof Arch – Another dual-phase steel component – the side roof arch – joins with the A-Pillar to form new Fiesta’s strong roof profile and provide a robust top attachment point for the B-pillar
■ Lower A-Pillar – The lower A-pillar is formed of very-high-strength, dual-phase 600-grade steel