Rogue’s Gallery: Nissan engineer takes a look at Rogue’s body materials strategy

Franklin, TN– A senior Nissan engineer lifted the curtain on the body materials that power the third-generation Nissan Rogue SUV at this year’s Great Designs in Steel Symposium (GDIS) in Novi, Michigan.

Repairers may already know this, but the third-generation Rogue, first introduced in 2021, contains significantly more advanced high-strength steel (AHSS) than its predecessor, including super-formable 980 and 1180 materials. super formable.

Nissan’s principal engineer, Weston Lawson, said the need for a roomier cabin and reduced weight on the Rogue led to the decision to build the model with 35% AHSS content, up from 13 % for the previous generation.

“This has been achieved primarily through the reduction of low-strength steel and the increase of 980 Super High Formability and 1180 Super High Formability materials, which are Nissan’s core technologies,” Lawson said.

He said using AHSS allowed engineers to forego what would have been a substantial increase in vehicle weight.

“Due to increased size and performance requirements, the mass increase would have been over 96 kg if the same hardware strategy as the previous Rogue had been used,” Lawson said.

Finding additional locations on the vehicle to replace traditional materials with aluminum, such as on the hood, doors and front fenders, also helped Nissan engineers reduce some of the Rogue’s weight.

“We also achieved mass reduction through increased use of joining technologies such as structural adhesives, and from the newly optimized platform,” Lawson said.

This material strategy did not help to lighten some of the Rogue’s load, but it also had a positive impact on the vehicle’s crash test ratings, as the use of 980 mega Pascal (MPa ) in the crossbeam increased section strength by 52 percent in the 60 km/h side impact test.

In addition, lowering the crossmember section height by 56 mm has made it easier to manage the side load in the event of a collision.

“The lower height reduces the bending moment from side impact and smoothly transfers the load to the limb,” Lawson said.

Lawson said the Rogue’s B-pillar is also very unique, in that it’s cold-stamped from a custom-welded blank of 980 super highly formable and 1180 super highly formable material.

“By using advanced high-strength steel with very high formability and a cold stamping production process, we can achieve the same benefits of hot stamping with much higher productivity,” he said. declared.

Nissan uses a laser welding process to create the blank which allows precise control of the hardness of the weld bead.

“This advanced high-strength steel solution balances crash safety while delivering approximately 15 percent mass savings over the previous Rogue design,” Lawson said.

Lawson concluded his presentation by saying that Nissan is working to lead the way in innovative AHSS applications.

“Nissan strives to continue to improve performance and make the vehicle lighter through increased use of advanced high-strength steels,” he said.

“These innovative designs, as we have seen, would not have been possible without material development.”