Exhaust Subsystem Durability Testing
Assess and validate the durability and expected life of exhaust subsystems to minimize warranty costs.
Assessing and validating the durability of automotive exhaust subsystems is critical to ensure components such as manifolds, catalytic converters, and piping withstand thermal, mechanical, and vibrational stresses over the vehicle’s life. These tests help reduce warranty claims and improve reliability. OEM engineers, Tier 1 suppliers, and specialized test laboratories perform durability testing to replicate real-world conditions, identify potential failures, and validate subsystem design before production release.
Test Methods
Durability testing of exhaust subsystems simulates real-world thermal cycles, vibration, and mechanical loading to evaluate component life and performance. Tests replicate engine torque, chassis vibration, and road-induced motion, while considering thermal expansion, corrosion, and joint fatigue. Components are subjected to multi-axis dynamic forces, high temperatures, and combined stress conditions to measure deflection, stress, and potential failure points. Laboratory systems provide precise, repeatable motion and force control, enabling extended-life testing under accelerated conditions. Data acquisition and analysis capture strain, displacement, and thermal response, allowing engineers to correlate lab results with vehicle-level performance, predict service life, and validate design improvements to minimize failure risk.
Test Results
Exhaust subsystem durability test results reveal fatigue life, stress distribution, thermal performance, and joint integrity for manifolds, piping, and converters. Manufacturers and labs use these data to optimize material selection, validate designs, reduce warranty claims, and ensure subsystem reliability under real-world operating conditions.
MTS Product Solutions
MTS Multi-Axial Simulation Table (MAST) Systems replicate the complex mechanical and thermal loading experienced by exhaust subsystems. Integrated with FlexTest® controllers, RPC® Connect software, modular test components, and high-performance hydraulic power units, MTS solutions provide precise, repeatable multi-axis motion, automated data acquisition, and control. Engineers can evaluate durability, fatigue, and thermal response accurately, supporting design validation, accelerated life testing, and improved exhaust system reliability.
Test Methods
Durability testing of exhaust subsystems simulates real-world thermal cycles, vibration, and mechanical loading to evaluate component life and performance. Tests replicate engine torque, chassis vibration, and road-induced motion, while considering thermal expansion, corrosion, and joint fatigue. Components are subjected to multi-axis dynamic forces, high temperatures, and combined stress conditions to measure deflection, stress, and potential failure points. Laboratory systems provide precise, repeatable motion and force control, enabling extended-life testing under accelerated conditions. Data acquisition and analysis capture strain, displacement, and thermal response, allowing engineers to correlate lab results with vehicle-level performance, predict service life, and validate design improvements to minimize failure risk.
Test Results
Exhaust subsystem durability test results reveal fatigue life, stress distribution, thermal performance, and joint integrity for manifolds, piping, and converters. Manufacturers and labs use these data to optimize material selection, validate designs, reduce warranty claims, and ensure subsystem reliability under real-world operating conditions.
MTS Product Solutions
MTS Multi-Axial Simulation Table (MAST) Systems replicate the complex mechanical and thermal loading experienced by exhaust subsystems. Integrated with FlexTest® controllers, RPC® Connect software, modular test components, and high-performance hydraulic power units, MTS solutions provide precise, repeatable multi-axis motion, automated data acquisition, and control. Engineers can evaluate durability, fatigue, and thermal response accurately, supporting design validation, accelerated life testing, and improved exhaust system reliability.
- Multi-Axial Simulation Table (MAST) Systems reproduce complex multi-axis loads, vibration, and motion on exhaust subsystems such as manifolds, piping, and converters. They provide repeatable, high-fidelity simulation of road, engine, and chassis forces to evaluate durability and predict service life.
- FlexTest Controllers deliver high-bandwidth, deterministic control for multi-axis subsystem testing. They ensure accurate application of mechanical, vibrational, and thermal loading, supporting repeatable durability tests and precise measurement of stresses, deflections, and fatigue behavior.
- Modular Components for Automotive Test Applications enable flexible configuration of test rigs for exhaust subsystem durability. They allow engineers to mount, support, and instrument manifolds, piping, and converters, facilitating realistic load paths and simplified adaptation to varying test requirements.
- RPC Connect Software streamlines test development, execution, and data analysis. It integrates motion profiles, monitors multi-axis responses, and enables correlation between lab and vehicle-level data for exhaust subsystem durability evaluations.
- Series 295 Hydraulic Service Manifolds provide stable, low-noise hydraulic distribution essential for MAST systems. They deliver precise pressure control to actuators, ensuring accurate, repeatable loading for high-fidelity durability testing of exhaust components.
- SilentFlo™ 515 & 525 Hydraulic Power Units supply quiet, stable hydraulic power for multi-axis testing. Their low acoustic signature and precise pressure control enable accurate simulation of dynamic loads on exhaust subsystems without introducing measurement noise.
