To meet the automotive industry’s increasing demand for lighter, more cost efficient products, AK Steel Corporation sees stainless steel as an effective material for structural components, including many light-weight body applications. AK Steel commissioned Troy, MI based Altair Engineering Inc. to design a lightweight tailgate using stainless steel that was easier to open and more resistant to dent and corrosion damage. The concept was designed to meet or exceed the performance of a current production carbon steel tailgate. This stainless steel design resulted in a 38% weight reduction over the carbon steel tailgate and can be a more cost effective solution to aluminum or other alternative light-weight materials.

Stainless steel can be the automotive industry’s answer for a lightweight material for a variety of body and structural applications. Stainless steel is well known for its ability to resist corrosion and has a strength-to-weight ratio three times that of low carbon steels. Other advantages include good formability, enhanced dent resistance and better durability performance. Also, the cost associated with manufacturing stainless steel stamped parts is generally less than other lightweight materials

Under normal use, tailgates are subjected to rough handling leading to paint abrasion, scuffing and are exposed to the corrosive elements. Additionally, tailgates are often not replaced after being damaged while still functional. Therefore, stainless steel should lengthen the life of tailgates, arguably the most abused closure panel. The lightweight tailgate also lowers lift and closing efforts. Additionally, most of the structural body repair practices prevalent in the industry are applicable to stainless steel.

In conclusion, there is a high degree of confidence that significant weight savings can be realized for pickup truck tailgates using stainless steel. This weight reduction does not compromise strength, improves durability and is an economical solution for lightweight initiatives.