Holistic testing and simulation integration
- Seamless integration of simulation and physical testing
- Improved model accuracy and validation quality through continuous feedback loops
- Efficient development and reliable durability assessment
Fatigue Testing Services
Discover our comprehensive Fatigue Testing Services, covering everything from small‑scale material specimen testing to full‑vehicle validation for heavy‑duty commercial applications.
How do Fatigue Testing Services ensure durability from component to full vehicle?
At Magna’s St. Valentin facility in Austria, we provide a complete workflow: from road load data acquisition and material testing to component validation and full‑vehicle fatigue assessment.
Our holistic approach integrates simulation and physical testing to maximize development efficiency and accuracy. Beyond fatigue life evaluation, our services include:
- Material analysis and model generation
- Method development and tailored test strategies
- Optimized test setups using FEM and MBS data
- Reduced system complexity through equivalent load generation
- Continuous improvement of simulation models through test feedback
With up to 40 actuators operating simultaneously, we can reproduce complex multi‑axial load scenarios. NDT analysis identifies critical stress areas during and after testing.
“Fatigue Testing is not just about validating durability, it is about understanding real-world behavior and improving performance across the entire system.”
Roman Aigner
Manager, Fatigue Testing
Real-world Fatigue Testing capabilities
Achsprüfstände
Unsere 6DOF-/12-Kanal-Achsprüfstände für eine Vielzahl von Fahrzeugtypen bilden die im Betrieb wirkenden Lasten auf Fahrwerkskomponenten realitätsnah ab. Zusätzlich können Umwelteinflüsse wie thermische und korrosive Belastungen überlagert werden. Darüber hinaus lassen sich aktive Komponenten in den Prüfaufbau integrieren.
What defines Magna's advanced Fatigue Testing capabilities in automotive engineering?
Tailored load application and test design
- Optimized test setups based on road load or FEM and MBS input data
- Reduced system complexity through equivalent load generation
- Precise replication of real-world operating conditions
Scalable testing from material to full vehicle
- Full coverage from material characterization to complete system validation Multi-axial testing with up to 40 actuators for complex load scenarios
- Reliable durability assessment across a wide range of applications
Advanced testing equipment and infrastructure
High-performance testing equipment
- 250 servohydraulische Aktuatoren
- Kraftbereiche zwischen 10N und 500 kN
- Frequenzbereich bis zu 2500 Hz
- Hub bis zu 500 mm
- 14 MTS-Mehrkanal-Steuerungssysteme
- MTS – RPC Pro
- FEMFAT LAB
- Über 40 Messverstärker mit mehr als 600 Messkanälen
Testing infrastructure and facilities
- 9 Fundamente (bis zu 500 Tonnen)
- Max. Prüflingsgewicht: 50 Tonnen (12 m × 7 m)
- Gesamtfläche: 2.344 m²
- Prüfbereich: 383 m²
- Installierte elektrische Leistung: (770 kW + 1280 kW (max. 2,05 MW))
- Installierte Kühlleistung: (152 kW + 240 kW)
- Flexibles modulares Prüfstandssystem
- Mehrere Lastrahmen (2,5 kN – 500 kN, max. 1000 °C)
- Resonanzprüfstand (150 kN PTP)
- Elektrodynamischer Shaker (125 kN, 1200 x 1200 mm)
Advanced Material Testing and Analysis
We investigate base materials and joint technologies, evaluating both quasi-static and highly dynamic material properties – including high-temperature behavior up to 1000°C.
Results are used to generate material models for FEMFAT and FEMFAT WELD, supporting accurate simulation results and durability validation.
Intelligent load data generation & measurement
Our end‑to‑end workflow includes sensor application, calibration, load spectrum generation, virtual iteration, and derivation of equivalent loads.
Our measurement services range from standard load-data acquisition to complex drivetrain analysis using telemetry. All instrumentation and calibration are performed in‑house, supported by FEMFAT LAB for data processing.
Key advantages of Magna's Fatigue Testing Services
Reduced development risk
- Early detection of potential failure points
- Improved confidence in product performance
Lower overall development cost
- Avoids late-stage redesigns and validation loops
- Reduces physical testing effort through optimized approaches
Faster time to market
- Shorter validation cycles through efficient workflows
- Accelerates decision-making with reliable data
Improved product quality and reliability
- Ensures consistent performance under real operating conditions
- Supports long-term durability across vehicle applications
