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Evolution of the New Ford Aerostar Impact Extruded Aluminum Wheel
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Abstract
Ford's continued effort to improve fuel economy in automotive applications has emphasized the need for lightweight components that retain all the toughness associated with Ford truck vehicle characteristics. The application of an impact extrusion process to wheel design and manufacture, for Ford Aerostar, provides strength, performance and style more efficiently than other traditional processes. It results in a valuable 33% weight saving over comparable HSLA steel wheels, and provides the customer with uncompromised value.
The Ford Aerostar Impact Extruded Aluminum Wheel was designed to be of one-piece construction, manufactured from a less than 1″ thick aluminum wafer-shaped blank. The process permits manufacture in half the steps of a conventional stamped steel wheel, and eliminates extensive machining required with forged or cast aluminum wheels.
This paper describes objectives, evolution of design, development, testing and integration of the manufacturing processes necessary for new wheel technology unique to the industry.
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Citation
Kapadia, M. and Eifert, R., "Evolution of the New Ford Aerostar Impact Extruded Aluminum Wheel," SAE Technical Paper 841694, 1984, https://doi.org/10.4271/841694.Also In
References
- Bambenek C. L. et. al. “1983 Ford Ranger Truck HSLA Steel Wheel” SAE Paper # 820019 International Congress Exposition Feb., 1982
- Aluminum Impacts Design Manual and Application Guide Forging and Impacts Division The Aluminum Association July 1979
- Warm Formed Wheel Metals Handbook 8th 5 American Society of Metals Forging & Casting 1970
- Alcoa Research Laboratory Data M.T. No. 021461-A
- Metals Handbook 2 9th
- Hix E. H. Jr. Brown R. H. Binger W. W. 916 926 Resistance of Aluminum Alloys to Corrosion Warm Formed Wheel Metals Handbook 8th 5 American Society of Metals