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
Axle Test Benches
Our 6DOF/12 channel axle test benches for a wide range of vehicles realistically display the acting loads on chassis components during operation. In addition, environmental influences such as thermal and corrosive effects can be superimposed to the mechanical loads. Moreover, active components can be integrated into the test setup.
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 servohydraulic actuators
- Forces between 10N and 500kN
- Frequency up to 2500Hz
- Stroke up to 500mm
- 14 MTS Multichannel Controller Systems
- MTS - RPC Pro
- FEMFAT LAB
- > 40 measurement amplifiers with over 600 measurement channels
Testing infrastructure and facilities
- 9 foundations (up to 500tons)
- Max. weight of specimen 50tons (12mx7m)
- Total area 2.344m²
- Testing area 383m²
- Installed el. power (770kW + 1280kW (max 2.05MW))
- Installed cooling power (152kW + 240kW)
- Flexible modular test rig system
- Multiple load frames (2,5kN – 500kN max. 1000°C)
- Resonance test bench (150kN PTP)
- Electrodynamic Shaker (125kN, 1200x1200mm)
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
FAQs – about Fatigue Testing Services
What are Fatigue Testing Services and why are they important in automotive engineering?
Fatigue Testing Aervices evaluate how materials, components and complete systems perform under repeated loading over time. By simulating real-world operating conditions, they help identify potential failure points and critical stress areas early in the development process. This is essential in automotive engineering, where durability, safety and long-term performance are key requirements. Fatigue testing supports reliable validation, reduces development risks and ensures that components meet demanding operational standards across their entire lifecycle.
How do Fatigue Testing and Simulation work together in vehicle development?
Fatigue Testing and Simulation are closely connected through a continuous feedback loop. Simulation models are used to define load conditions and optimize test setups, while physical testing validates these assumptions under real conditions. The results from testing are then used to refine simulation models, improving their accuracy over time. This integrated approach enables more efficient development, reduces the need for repeated physical testing and leads to more reliable durability predictions.
What types of components and systems can be validated through Fatigue Testing?
Fatigue Testing services cover a wide range of applications, from material specimens and individual components to complete vehicle systems. Typical test objects include chassis components, structural parts, powertrain elements and assemblies exposed to complex load conditions. Advanced testing setups allow multi-axial loading and the simulation of real-world environments, ensuring that both simple and highly complex systems can be validated under realistic conditions.
How is real-world load data used in Fatigue Testing?
Real-world load data is a key input for accurate Fatigue Testing. It is collected through sensors and measurement systems that capture parameters such as strain, acceleration and displacement during vehicle operation. This data is processed, calibrated and transformed into load spectra and equivalent load cases that can be applied in test rigs. By using real operating data, fatigue testing achieves a high level of accuracy and ensures that validation results closely reflect actual vehicle usage.
