Process and Material Options for Automotive Chassis Aluminum Castings

Aluminum castings have been replacing iron castings and steel fabrications with significant weight savings. Casting designers face the challenges of selecting the casting process best suited for the casting configuration and selecting the alloy most suited to meet the part function.

Casting processes currently proven and applicable to high integrity aluminum castings are briefly described. The available alloys are listed along with their properties. General guidelines are offered for the selection of casting processes and alloys. The scope for further work is defined. The emerging technologies to be harnessed are identified.