Body: Rigid basis thanks to aluminium hybrid construction

Mar 10, 2017

Bodyshell reinforcements ensure the high rigidity of the new E-Class Coupé, allowing agile, sporty handling characteristics.

Dispensing with a continuous, visible B-pillar allows a visually consistent side window line, which underscores the dynamic proportions of the E-Class Coupé. Nonetheless, to give the body structure the necessary rigidity, Mercedes engineers took additional measures in the areas of the side walls and especially the roof frame. The most important were as follows:

  • a three-section roof cross-member at the front, with an integrated reinforcing component,
  • a system of struts above the rear seat cross-member,
  • an additional double sleeve in the A-pillar,
  • side members with a larger cross-section than those in the Saloon,
  • and also greater material thicknesses and ultra-high strength materials in some areas.

Other measures ensure a low noise level that is exemplary in this segment. For example, the floor and firewall were given additional rebates to minimise low-frequency noises, especially road roar.

Intelligent material mix

The bodyshell is of aluminium hybrid construction. The major part of the bodyshell is of diecast aluminium and sheet steel. The front wings, bonnet and boot lid are of sheet aluminium. The proportion of materials in percent by volume (in brackets: percent by weight):

Aluminium (sheet metal and cast)                                                   26 (11)

Hot-formed and partially hot-formed steel components %            13 (16)

Ultra-high-strength sheet steel                                                        11 (13)

High-strength adhesives are used in large measure for strong joints between components, sometimes in combination with mechanical joining techniques. This also helps to increase the rigidity of the bodyshell.