Based on the experience gathered with the Zonda F and Zonda R programmes, MHG Group was able to meet the strict requirements for the exhaust system for the Pagani Huayra. While a standard muffler in the automotive industry is built in automated processes, the approach to create the titanium-version muffler of the Pagani Huayra could not be more different.
Depending on the exhaust temperatures a single component is exposed, a specific grade of aerospace-titanium alloy is chosen to make the parts durable at highest temperatures.
Precise TIG welding process ensures the reliability of the connections and joints. To create the distinctive elliptical shape of the Huayra's muffler, the tube is positioned in a hydro-forming tool, where high-pressure (2100bar) liquid makes it expand into the moulds, giving it the required shape. Many parts with complex geometries and critical sections are hydro-formed, rendering welding in certain areas unnecessary, therefore improving reliability, as "no-welding, is the best welding".
The hydro-formed part, tubes and interiors are then assembled by hand to become the final muffler. Only a handful of the best welders in the industry are capable of creating these masterpieces. The assembled muffler is polished before it is given the signature dark blue shine. To achieve this, a heat treatment process is required. Only the combination of exact temperature and exposure to heat will result in the required colour. Any fingerprints or impurity in the material, and the muffler would not pass quality demands. After the Pagani signature has been sandblasted, the parts are ready for the final assembly on the jig, again, by hand. Once assembled, the complete exhaust assembly weights less than 10kg and stands as an automotive piece of art by itself.
Located in the town of Heubach, Germany, MHG Group is a special exhaust manufacturer with over fifteen years of experience in creating the most successful F1 and endurance prototype exhaust systems.
Official Website: http://www.mhg-fahrzeugtechnik.de/