AP IMPACT: Cars Made in Brazil Are Deadly

by Bradley Brooks (Associated Press) The cars roll endlessly off the local assembly lines of the industry's biggest automakers, more than 10,000 a day, into the eager hands of Brazil's new middle class. The shiny new Fords, Fiats, and Chevrolets tell the tale of an economy in full bloom that now boasts the fourth largest auto market in the world.

What happens once those vehicles hit the streets, however, is shaping up as a national tragedy, experts say, with thousands of Brazilians dying every year in auto accidents that in many cases shouldn't have proven fatal.

The culprits are the cars themselves, produced with weaker welds, scant safety features and inferior materials compared to similar models manufactured for U.S. and European consumers, say experts and engineers inside the industry. Four of Brazil's five bestselling cars failed their independent crash tests.

(T)he U.S. recorded 40 percent fewer fatalities from car wrecks in 2010 compared with a decade before. In Brazil, the number killed rose 72 percent, according to the latest available data.

"The manufacturers do this because the cars are a little cheaper to make and the demands of the Brazilian consumers are less; their knowledge of safety issues is lower than in Europe or the U.S."

Manufacturers earn a 10 percent profit on Brazilian-made cars, compared with 3 percent in the U.S. and a global average of 5 percent, according to IHS Automotive, an industry consulting firm.

Only next year will laws require frontal air bags and antilock braking systems on all cars, safety features that have been standard in industrial countries for years. The country will also have new impact regulations on paper, at least; Brazilian regulators don't have their own crash-test facility to verify automakers' claims about vehicle performance, nor are there independent labs in the country.

General Motors had no comment other than to say that its cars in Brazil are legal.

An engineer for a major U.S. automaker, speaking only on condition of anonymity for fear of losing his job, said he has watched for years as his company failed to implement more advanced safety features in Brazil, simply because the law did not require them.

""The automakers are pleased to make more profitable cars for countries where the demands, whatever they may be, are less rigorous," he said. "It happens everywhere — India, China and Russia, for example."

"The electricity used in building a car is about 20 percent of the cost of the structure," said Marcilio Alves, an engineering professor at Brazil's premier University of Sao Paulo and one of the few independent researchers in the nation looking at car safety.

"If you save on electricity, you save on cost. One way to save electricity is either reducing the number of spot welds or using less energy for each spot weld made. This affects structural performance in the event of a crash."

In fact, in more than a dozen interviews with accident victims left paralyzed after crashes, not one considered taking legal action against vehicle manufacturers.

That's in part a reflection of the lack of police investigations into car accidents, the majority of which, like Lopes', only result in simple "occurrence bulletins" that include minimal information.

But it's also indicative of the deference Brazil's new middle class consumers show to automakers and most other industries.