Collision Repair Training | Australia
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Collision Repair Training | Australia
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Current Events/News: Advantage Online: 2005 Archives
CHEVROLET CORVETTE Z06 ON THE HORIZON
June 27, 2005 - The soon-to-be-released Chevrolet Corvette Z06 is built using some new manufacturing processes and materials that may become a challenge when collision repairs must be performed. The Chevrolet Corvette has long been called GM’s muscle car, and the 2006 Corvette Z06 emerges as the fastest and most powerful production vehicle GM has ever built (see Figure 1). Aluminum Structure What is so different between the 2006 Corvette Z06 and its predecessors? For starters, the curb weight. GM engineers, in conjunction with the Chevrolet Corvette factory racing team, uses several weight-reducing materials to equally balance the vehicle and compensate for the additional weight of the 500 horse powered 7.0 L, 427 cubic inch displacement engine that is equipped with a dry sump engine lubrication system to provide consistent lubrication during aggressive driving (see Figure 2). The overall weight of the Corvette Z06 is tipping the scales at 1,420 kg (3,130 lb), compared to 1,647 kg (3,631 lb) for the steel counterpart. This is, in part, due to the use of aluminum for the structure. Dimensionally, the vehicle frame is very close to the steel-structured Corvette (see Figure 3), but the similarities in the frame stop there. The frame rails are made from hydroformed aluminum alloy with aluminum castings and stampings that are GMA (MIG) welded, laser-welded, and riveted together (see Figure 4). The thickness of the material on the aluminum rails measures four millimeters (see Figure 5), as opposed to three millimeters on the steel frame rail (see Figure 6). Different straightening and welding techniques will be required for structural repairs on the aluminum frame. During the repair process, the self-piercing rivets are replaced with a coated blind rivet or GMA (MIG) plug welds. The rivets will have a GM part number and will be available at any GM dealer. Specific service and collision repair procedures will be made available on the GM Service Information web site. Subscriptions can be obtained by following the General Motors link on the technical information area of the I-CAR web site. Carbon Fiber The other significant weight-reducing material used is carbon fiber. Carbon fiber is used to make the front fenders, outer portion of the inner wheelhouse, and the floorboards. The fenders are 1.2 mm thick as opposed to the traditional reinforced reaction-injected molded (RRIM) plastic fenders from the C5 Corvette that measure three millimeters thick. The weight of each front fender is a mere 1.2 kg (2.7 lb). The rigidity of carbon fiber for the fender application also reduces the need for reinforcements required for the thermal expansion characteristics of RRIM, thus creating a secondary weight savings. The floorboards are made with a balsa wood core encased in carbon fiber sheets (see Figure 7). The floor used on the C5 Corvette is also made with balsa wood, but is encased in a heavier and thicker sheet molded compound. Other notable changes include the use of magnesium alloy castings for the engine cradle and roof support. The roof support adds rigidity to the vehicle body and is not removable. The braking system uses six piston calipers on the front with six individual brake pads to reduce heat buildup. Cooling ducts for the brakes are designed into the fenders and quarter panels and are fully operational (see Figure 8). Restraint System Protecting the vehicle occupants during a collision is an advanced restraint system with driver and passenger airbags, seat-mounted airbags, and seat belt pre-tensioners. The restraint system also has a passenger presence system (PPS) that identifies the presence of an occupant in the passenger seat. The PPS uses a silicone bladder and weight sensors in conjunction with a seat belt tension sensor to detect the presence of a child safety seat (see Figure 9). The PPS communicates with the sensing and diagnostic module (SDM) to determine if the passenger restraint system will be enabled or disabled. I-CAR Training Program I-CAR, in cooperation with General Motors Service Technical College, has developed a four hour I-CAR Live training program that gives specific details on repairing collision damage to this vehicle. The program Collision Repair Overview for the Chevrolet Corvette Z06 (GEN01) has been completed and will be available soon. Visit the I-CAR web site to see when it will be scheduled in your area.
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