Key Life Tests for Automotive Design Validation

The Durability Key Life testing is an essential step in determining the expected life of a vehicle. It increases repeatability and reduces risk exposure by detecting defects at an earlier stage in the vehicle development process, whether of the full-vehicle, subsystem or component level is tested. The paper presents the characterization of the Accelerated Durability Key Life Test method and post-test measurements made after testing, applied on the automotive side doors, aiming to support the evaluation of the real-life of a vehicle component at an accelerated pace. The main objective of the paper is to validate the design of automotive components, by using the Key life test method and related test measurements required by the working procedure. The paper intends to highlight possible failure modes and the factors that contributed to it. Thus, the paper presents the detailed process of the key life test method and the measurement results of gap and flushness, torque and shut speed of the side doors. Following the results, the need to meet customer expectations in terms of quality, durability and reliability of the Key life test has increased.