A sports coupé of decided personality and flair, yet also a cutting-edge car in terms of equipment, power units and mechanicals. This was the brief given to the Alfa Romeo engineers and technicians. To achieve its goal, Fiat deployed its best resources and ensured that maximum quality and reliability standards were applied throughout the product development and construction process.

It also developed a profitable co-operative relationship with its outside suppliers and some Group Companies including Magneti Marelli, Teksid, Comau, Elasis and the Fiat Research Centre. Out of this cooperative venture came the many innovative solutions that make the Alfa GT the new benchmark in its category.


Magneti Marelli

Magneti Marelli made available the cream of its new products for the new sports coupé. More specifically, the Alfa GT is fitted with the latest version of the Selespeed power assisted steering system that is the pride of Magneti Marelli technology. The system's first application on a standard production car was on the 156 model from which the Alfa GT is derived.

The fast and reliable Magneti Marelli Selespeed gearbox is derived directly from F1. The system was tested and developed in conjunction with Ferrari, firstly on F1 single-seaters and then on the 355 - hence its designation 'F1'.

The front light clusters are also a product of Magneti Marelli technology. The Automotive Lighting engineers designed the extensive headlights that help make the car's penetrating, aggressive front end immediately recognisable and are available in a dual halogen and gas discharge bulb version. Comfort and safety are also assured by a Magneti Marelli suspension that includes a front system (right and left side and front crossmember assembly) and a rear system (axle and wheel unit components).


Teksid

Through its subsidiary Meridian Technologies Inc., Teksid produces an underfacia beam in magnesium at its plant in Verres (Aosta). The use of this specific structural component allows a significant reduction in product weight: 60% less than a conventional steel beam. It also absorbs vibrations more effectively for greater comfort.

Teksid also supplies the grey iron cylinder blocks produced in its Crescentino plant (Vercelli), for the 1.8 Twin Spark, 1.9 JTD and 2.0 JTS engines.

Comau

The production plants Comau used to produce the Alfa 147 and 156 bodies were so flexible that the Pomigliano assembly lines could be quickly reconfigured for the GT model. It was therefore possible to assure the same quality standards already achieved on tried and tested Alfa Romeo products from the outset.

Elasis

A shielded anechoic chamber measuring 23 m x 11 m x 9 m was set up at the EMC (electromagnetic compatibility) laboratory at the Pomigliano d'Arco centre that is unique in Italy and at the forefront of European technology. This was used to perform a set of extremely tough tests that involved subjecting the Alfa GT car to electromagnetic stresses 25 times as intense as the maximum EM pollution levels permitted by Italian legislation.

Static and dynamic characterisation rigs were used to adjust and optimise the main systems that affect interior noise (body, facia and trim elements) (acoustic comfort). In particular, subjective and objective measurements were performed on a dynamic characterisation rig (Four Poster rig) within a semianechoic environment where the car tyres were subject to vertical excitation using plates. Acoustic performance was also checked by putting the Alfa Romeo GT through ageing cycles on a road simulator located in a climatic cell (cobble cycle).

The Selespeed system on the Alfa Romeo GT 2.0 JTS Selespeed also benefits from the same innovative software created for the Alfa 156 GTA Selespeed. This was calibrated using new qualitative parameter objectivisation methods and checked by performing reliability/durability tests under the heaviest town traffic conditions.

On automatic versions of the Alfa GT, engine and gearbox control systems were tuned to produce systems that give the car the feeling of a sporty drive. The torque based engine control system is managed by the car's electronic systems and robotised gearbox versions are set to racing standards. The automated clutch management and operations determine a high-tech, high-performing product.

PowerTrain integration is managed by Hardware In The Loop simulation environments where PowerTrain elements are simulated and the necessary checks are performed on the electronic control units and software inside.

Fiat Research Centre

Innovative procedures are required to build cars that offer extraordinary no-holds-barred performance - or any successful car for that matter. We allow our sporty Alfa customers to guide the design of their dream car, hand in hand with the designer and tester.

The outcome is a brand new car concept that offers considerably more dynamic performance, driving satisfaction and comfort than its competitors under all service conditions and for all drivers - along with the greatest safety, quality and reliability.

The Fiat Research Centre customised its own innovative design procedures to the distinctive traits of the Alfa Romeo brand and conveyed them to the team that designed and produced the new sports coupé. Some of these are described below.

For the vehicle

• First and foremost, the car's extreme dynamic performance qualities (super-handling). These allow outstanding performance in terms of car handling and stability, features peculiar to Alfa cars and fundamental to the Driving Satisfaction they offer. These traits, also achieved through the application of the most recent objective on-road simulation and testing methods, allowed the suspension and controls (steering, brakes) to be carefully designed for a satisfying, predictable drive under all speed, manoeuvre and grip conditions.
• The Alfa style cockpit and interior appointments are the result of rigorous interpretation and customisation of the physical ergonomic criteria that underpin the design of the main controls (steering wheel, pedals, gearbox), driving position, car access and proper use of space, including optimisation of seats to ensure postural, hygrothermal, vibrational and dynamic comfort.
• To underscore Alfa's distinctive nature and custom features, cognitive ergonomic devices were used to guide the design of communication interfaces (secondary controls, control panel, display) so that Alfa customers could be put behind the wheel of the new car from the design stage through the use of Virtual reality laboratories. We are all aware of the importance of aerodynamics to sports performance: computed dynamic flow methods allowed us to optimise the vehicle's exterior aerodynamics for improved performance and less aerodynamic noise while also allowing interior comfort and wellbeing to be optimised in terms of climate and air quality by improving air flow inside the passenger compartment and helping to develop the specifications of single and dual-zone air distribution systems. Last but not least, noise levels: not all noises are unpleasant: music is not, for example, and the sound of an Alfa Romeo engine certainly is not. NVH (Noise, Vibration, Harshness) reduction methods aim in this case to minimise interference (to alleviate stress and help driving alertness) while also enhancing the characteristics that allow you to communicate with and manage the power of a true GT.

For the engines

The basic design layout (particularly of the 1.9 M-Jet 16v and 2.0 JTS engines) and their subsequent distinctive high-performance customisation are determined by innovative technologies and computing procedures that allowed the development of:

• multipoint injection systems for Diesel engines that inject fuel directly into the combustion chamber (Multijet);
• engine control strategies for simultaneous optimisation of performance, emissions and fuel consumption;
• direct petrol injection to ensure a stoichiometric mixture;
• thermal dynamic flow simulation of the combustion process in petrol and Diesel engines;
• structural analysis of critical power unit components with the aim of improving reliability and acoustic/vibrational comfort.

For telematic functions

These are clearly aimed at safe, environmentally-sound mobility:

• The Navigation System and Mobile Phone Test procedures used to determine telematic system design standards assure quality and reliability;
• development of a communication protocol for access to services offered by CONNECT;
• design of a man-machine interface for in-car telematic functions, to facilitate use by the driver and to supply information in a non-distracting manner;
• design and definition of voice command system specifications.
• EMC Engineering procedures and Anechoic Chamber Tests to ensure that the on-board electronics operate correctly in the presence of electromagnetic interference and that electromagnetic pollution standards are met.