Development Techniques for Automotive Cast Components

This paper outlines the development process for cast components used in structural automotive applications. Typical design characteristics such as STRENGTH, STIFFNESS, CRASHWORTHINESS, FATIGUE and manufacturability for COST are discussed. Appropriate methods for material selection, part consolidation, development process and tools, product specification and nondestructive testing, prototype and product validation testing are covered in details. As aluminum alloys are the most commonly used lightweighting materials, the VRC/PRC process, invented by Alcoa, will be used in most of the case studies presented. This article constitutes a reference for design engineers and purchasing engineers to select material and manufacturing process that best suit their applications based on cost and performance.