This study focuses on weld integrity of stainless steels in bus coach appli
cations, Safety aspects have been studied based on fracture mechanics and i
mpact toughness testing. Fatigue resistance of welded rectangular hollow se
ction (RHS) profiles was evaluated according to the Eurocode 3 (1992) fatig
ue standard. Corrosion resistance was studied by salt-spray chamber tests i
n a deicing salt atmosphere and by field testing for 3 years under an urban
bus. The mechanical tests show that austenitic stainless steel EN 1.4310 (
AISI 301) is a superior material, and a low-C 12% Cr alloyed stainless stee
l EN 1.4003 is also a competitive material in bus coach applications. Accor
ding to the life cycle cost (LCC) calculations, stainless steels are compet
itive compared with carbon steels or aluminum.