Technical Report The Construction of Alloy Wheels
Introduction
Aluminium alloy wheels are now used in all branches of Motor Racing,
ranging from Touring cars and Rally cars to Formula One cars. The
Alloy wheels offer far superior mechanical properties than the
conventional steel wheels formerly used. These benefits include
reduced un-sprung weight, i.e. not held by the suspension, providing
more precise steering input and improved responsiveness.
Alloy wheels also improve acceleration and braking due to the
reduction of weight. The added strength of a quality alloy wheel can
significantly reduce wheel/tire deflection in cornering. This is
particularly critical with a vehicle equipped with high performance
tires where lateral forces may approach 1.0g. The metals in alloy
wheels are excellent conductors of heat - improving heat dissipation
from the brakes - reducing risk of brake fade under demanding
conditions. Additionally, alloy wheels can be designed to allow more
air to flow over the brakes, this can help cooling.
The alloy used in the finest road wheels today is a blend of aluminium
and other elements. The term "mag wheel" is sometimes incorrectly used
to describe alloy wheels. Magnesium is generally considered to be an
unsuitable alloy for road usage due to its brittle nature and
susceptibility to corrosion.
Nowadays, there are basically three ways in which alloy automotive
wheels are constructed. The three types can be referred to simply by
cast, billet and forged.
Casting is a relatively inexpensive way to produce a high-quality,
fairly strong alloy wheel; many aftermarket alloy wheels designed for
street use are made this way. Billet wheels are machined from a solid
chunk of material and forging uses intense heat and pressure to
transform a slug of alloy material into the final shape of a wheel.
This report will focus mainly on the casting processes used.
Casting Processes
The most common process of constructing alloy wheels is One-Piece
Casting, there are a number of methods to do this, and the most basic
is Die Casting, this process is used world wide throughout the casting
industry and is not exclusive to alloy wheels.
The Die Casting process uses a permanent mould usually made of metal,
which generally means that there is high tooling costs compared to
other methods of casting, but this high tooling cost is combined with
low production costs. This means that die casting is suitable for
products with a large production number.
There are four main processes in the die casting family, these are:
Gravity Die Casting
Pressure Die Casting
Low Pressure Die Casting
Squeeze Casting
Gravity Die Casting
This process is the most simple of the four, the mould or die, which
is generally made in two halves, is filled with molten metal, in the
A wide variety of coating alloys and wrought alloys can be prepared that give the metal greater strength, castability, or resistance to corrosion or high temperatures. Some new alloys can be used as armor plate for tanks, personnel carriers, and other military vehicles.
-Developed and implemented strip casting overseas to eliminate a step in the steel making process
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