Dongfeng DFAC CAPTAIN truck parts Front collision beam 8406030-T1500

Built to withstand low-to-medium speed collisions (up to 30km/h) and protect critical components (radiator, engine, cab), the beam is crafted from Q460C high-strength low-alloy steel—specifically designed for automotive safety structures. This material delivers a minimum yield strength of 460 MPa, tensile strength of 550–720 MPa, and impact toughness of ≥40 J at -40°C, enabling the beam to absorb up to 12kN of impact force before deformation (exceeding DFAC’s 9kN safety requirement for front collisions). The steel undergoes quenching and tempering (890°C quenching, 580°C tempering) to enhance hardness (HB 200–240) and fatigue resistance, passing 2 million vibration cycles (equivalent to 150,000 km of road use) without crack formation. Compared to Q355 steel beams, this Q460C design improves impact absorption by 35%, critical for DFAC CAPTAIN trucks operating in urban logistics or construction zones with high collision risks

Engineered to maximize impact energy dissipation and minimize damage to the chassis, the beam features a closed “U-shaped” cross-section (120mm width × 80mm height × 6mm wall thickness) with integrated reinforcing ribs (5mm thick, spaced 150mm apart). This structure allows the beam to deform in a controlled “crumple zone” pattern during collisions, absorbing 60% of impact force before transferring residual energy to the frame rails. The beam’s ends are welded to 8mm-thick steel mounting plates (laser-cut for precision), spreading localized impact stress over a 100mm-wide area on the frame—reducing frame deformation by 45% vs. beams with thin mounting points. Unlike flat-plate beams that bend unpredictably, this optimized design ensures consistent collision performance, meeting China’s GB 26512-2011 commercial vehicle front impact safety standard

Designed to resist corrosion from road salt, mud, and rain (common in undercarriage environments), the beam undergoes a four-stage protective process. First, a shot blasting treatment (SA 2.5 grade) removes surface rust and contaminants, creating a rough texture for coating adhesion. Next, a zinc phosphate conversion coating (60μm thickness) forms a corrosion-resistant base layer. Then, an electrophoretic primer (80μm) is applied to seal the steel surface, preventing moisture intrusion. Finally, a high-gloss epoxy powder coating (70μm) is baked on (180–200°C curing) to resist chipping, chemical damage (e.g., diesel, road deicers), and UV degradation. This coating system passes 1,500 hours of neutral salt spray testing without rust or peeling, ensuring durability in snowy, coastal, or mining regions where the DFAC CAPTAIN often operates

Designed for efficient replacement by fleet technicians, the beam simplifies installation with user-friendly details. All mounting holes (12 total, 14mm diameter) are drilled to H8 tolerance, ensuring perfect alignment with the DFAC CAPTAIN’s M14 frame bolts—avoiding cross-threading during assembly. The beam’s weld joints (between the main body and mounting plates) are ground smooth to eliminate sharp edges that could damage adjacent components (e.g., wiring harnesses, brake lines). The package includes 12 grade 10.9 high-tensile bolts (M14×60mm) and lock washers, pre-lubricated with molybdenum disulfide to prevent thread galling in high-temperature environments. Installation takes 45–60 minutes: remove the old beam by detaching the bumper and frame bolts, align the new beam’s reference marks with the frame rails, torque the bolts to 220 N·m (per OEM specs), and verify bumper alignment. Each unit undergoes dimensional inspection via CMM, impact testing, and weld quality checks, backed by a 24-month warranty against defects (e.g., cracking, coating peeling, dimensional inaccuracies)