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The battle of the metals
Multi-link suspension design
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The ULSAS multi-link design had a 30% cost savings and slight mass advantage over the aluminum-intensive benchmark.
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Multi-link suspensions are most often used in the luxury car segment because of the superior dynamics and ride quality they provide. The ULSAS multi-link unit is the only Lotus design with an aluminum benchmark and the only one to include a subframe. The new design showed a 30% cost savings with a slight mass advantage over the aluminum benchmark. It features large hollow section lower arms formed by welding together two 2.0-mm (0.08-in) gauge, 300-MPa (44-ksi) HSS clamshell stampings. The upper and lower stampings are symmetrical. The links are made of 16 by 1.5-mm (0.63 by 0.06-in) and 17.5 by 1.5-mm (0.69 by 0.06-in), 250-MPa (36-ksi) HSS tubes.
The subframe is a stamped assembly of five major components and several reinforcements using steels ranging in gauge from 1.2 to 2.0 mm (0.05 to 0.08 in) and yield strengths between 200 and 400 MPa (29 and 58 ksi). The subframe is joined by a combination of laser, MIG, and spot welding. The stamped control arm halves are made of 2.0-mm (0.08-in) gauge, 300-MPa (44-ksi) HSS and are butt welded together by MIG and spot welding. The forged knuckle is made of 750-MPa (109-ksi) ultra HSS.
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