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For the first time in volume production, supporting welded aluminum structures were used in the chassis area. Metal sheets, extruded sections, longitudinally seam welded pipes and castings were used as semi-finished products. Extensive strength tests, in cooperation with the Design Department and Production, resulted in sophisticated design solutions. In considering matters important to the customer, these solutions were substantiated through numerous examinations which are especially necessary for aluminum.

Lightweight vehicle design requires fast and economical fatigue testing especially for suspension components. Spring testing, so far, has been a slow and energy intensive process. IABG* has developed a new machine which tests springs with a frequency of up to 15 Hz. It features low power consumption in spite of the long stroke needed for suspension springs, and it tests four springs simultaneously using a unique power-compensating test principle. Correct testing of linearily compressed springs as well as springs that are compressed along an arc is possible because the machine is designed to allow the duplication of any suspension geometry. Even the influence of different assembly positions of the spring within a given suspension system can be evaluated. Test results of the more than 20 machines already in service are presented.