Created by Andrew Poulios6/18/ Dodge Journey Body Structure Equipment and Tool Institute June 18, 2008 Andrew Poulios Body Structures Engineering

Created by Andrew Poulios6/18/2008 UHS S HSALPLAHS S KEY: Body Material – Steel Summary

Created by Andrew Poulios6/18/2008 Body Material - Parts Summary Part Usage*: - Hot Stamp Boron Steel………….10 Parts - B-Pillar - B-Pillar Reinforcement - Windshield Frame - Door Beams - Dual Phase 340/590 Steel………21 Parts - Front Rails - Dash Crossmember - Rear Rails - Tunnel Cap - Front Floor Crossmember - 80 ksi HSLA steel……………….. 9 Parts - 50 ksi HSLA steel………………..40 Parts - 40 ksi HSLA steel……………….. 13 Parts - Aluminum………………………… 6 Parts - SMC Fiberglass…………………. 3 Parts Breakdown of Material Usage Breakdown of BIW Components by Mass: % Mild Steel % mix of hot stamp, dual phase and high strength steel - 2.5% SMC (Fiberglass) - 1.5% Aluminum

Created by Andrew Poulios6/18/2008 Steel Types HS Steel Galvanneal Coated Dual Phase 340/590 MPa Steel: Front rails Rear rails Dash crossmember Front floor crossmember Benefits Weight optimization ● Impact energy absorption Parts: Front Rails:8 parts Dash x-member:1 part Tunnel cap:1 part Front floor x-member:1 part Rear floor sidemembers2 parts Front seat x-members 2 parts Rear Rails 6 parts Total21 parts Tunnel Cap Rear floor sidemembers Front Seat crossmembers Parts: Ft Tunnel RailRoof Bow Shock Cap ReinfCowl Side Roof Side RailBody Ft Hinge Pillar B-Pillar Inner B-Pillar Lower Reinf C-Pillar Lower ReinfFt Dr Lower Hinge Assy Ft Dr Upper Hinge Assy RR Dr Lower Hinge Assy RR Dr Upper Hinge Assy Fuel Tank Attach Bkt 2nd Row Seat Anchor Plt RR Spring Cap RR Susp ReinfShipping Tie Down Bkt Ft Rt Crush Can Inner Ft Rt Crush Can Outer Ft Lt Crush Can Outer Ft Lt Crush Can Inner Hood Hinge Ft Bumper Beam RR Bumper Beam Sill Inner Sill OuterSill Reinf Total:28 parts Benefits Weight optimization ● Impact energy absorption AHHS: Dual Phase Benefits - Improves roof crush strength- Improves door crush resistance - Optimizes weight distributions - Provides passenger compartment Integrity during front and side impact modes Parts: - Door Impact Beams - B-Pillar- B-Pillar Reinforcement - Windshield Frame UHHS: Hot Stamped

Created by Andrew Poulios6/18/2008 Highlights of Dodge Journey’s body structure include the following features: Dodge Journey’s body structure contains a combined 38.4% by mass of hot stamped and high-strength steels for optimized weight and structural performance. The next generation of elastic adhesives from Dow Automotive adds strength to joints during an impact while being easier to use during the assembly process compared to the first generation “Blue Glue” that was first introduced on Dodge Caliber Effective joint designs create a rigid structure, minimizing NVH inputs to the passenger compartment and increasing body stiffness through enhanced structural continuity More crush space added to the engine box by moving the power-train 50mm forward From the B-pillar forward, Dodge Journey’s upperbody has common architecture with Sebring/Avenger with components sized appropriately for structural performance The doors feature several reinforcements for side-impact protection: Stamped belt reinforcements on the front doors and rear doors Hot-stamped beams in front and rear doors Stamped reinforcements that connect the belt reinforcements to the hot stamped beams Body Structure Highlights

Created by Andrew Poulios6/18/2008 UHS S HSALPLAHS S KEY: Load Path: Underbody *Similar to JS41 Extensive use of dual-phase steels in the front and rear rails, tunnel reinforcement and sills permit these components to handle greater loads than conventional steels for more effective impact energy management while still being relatively easy to stamp and control dimensionally Jack Points

Created by Andrew Poulios6/18/2008 UHS S HSALPLAHS S KEY: Load Path: Upperbody High strength and hot stamped boron steels are used extensively in the body side inner for effective side impact energy management and Hot stamped steel A-pillar and B-pillar reduce upper body weight by 30 lb. (14kg) compared to mild steel equivalents

Created by Andrew Poulios6/18/2008 Feature Highlights New lighter “D-section” bumper assemblies compared to the prior “B section” bumper assemblies used on Chrysler Group vehicles are designed to perform energy management in a small space The bumpers are designed to accommodate the most stringent of truck classified vehicle requirements. (Dodge Journey is classified as an SUV/light truck) The front bumper is contained in the front end module. The new, lighter D-section bumper assembly features 80 Ksi roll formed steel for vehicle protection in low speed impacts. Bumper System

Created by Andrew Poulios6/18/2008 Front End Module Dodge Journey’s front end module represents the next phase in evolution from the Chrysler Sebring/Dodge Avenger front end module. This front end module features the highest level of component integration to date within the Chrysler Group. Features and Benefits The benefits of this attachment scheme are complexity reduction and ease of service by eliminating many unique fasteners. There are one screw attachment and snap-in features for many components that are integrated in the module. Front-end module attaches to the body at bumper beam and top (highlighted in green) attaches to load beam The components mount on a hybrid structural armature that spans the front of the vehicle, replacing multiple steel parts that are traditionally welded together. The backbone starts with a stamped steel C-section beam over molded with 20 percent glass-filled polypropylene. A latticework mesh inside the C-section provides the component’s structure. FEM COMPONENTSFEM

Created by Andrew Poulios6/18/2008 QUESTIONS