Aluminum Castings in the Automotive Industry – Application Examples

Aluminum has become one of the core materials of modern automotive engineering. Low weight, strength and the ability to cast complex shapes make it possible to build lighter, more economical vehicles. Below we show where aluminum has replaced steel and cast iron.

Advantages of aluminum castings in cars

• Light weight – aluminum has about one-third the density of steel, and lighter parts mean lower fuel or energy consumption.
• Strength – aluminum casting alloys, especially after heat treatment, are strong enough for many load-bearing parts.
• Design freedom – a single casting with ribs and channels can replace several joined parts.
• Recycling – aluminum can be remelted repeatedly, and remelting requires only a small fraction of the energy needed to produce primary aluminum.

Examples of applications of

Engines and drivetrain

Aluminum is used to cast cylinder heads and engine blocks, transmission and clutch housings, oil pans and pump bodies. A lighter engine and transmission reduce the weight of the entire vehicle, and aluminum dissipates heat well.

Suspension and wheels

Cast aluminum control arms, steering knuckles and wheels reduce unsprung mass, which improves handling and ride comfort.

Body and electromobility

Car bodies use cast structural nodes, pillars and brackets, and electric vehicles use housings for batteries, motors and power electronics. Large structural castings can replace many stamped and welded steel components.

Aluminum castings from our foundry

We cast aluminum alloys to order, to your drawing or 3D model: in permanent molds (from 0.1 to 50 kg), in sand molds (from 1 to 100 kg) and by high-pressure die casting (in runs of up to 100,000 pcs per year). We machine the castings on CNC machines and powder coat them. If you need an aluminum housing, bracket or body, send us your drawing for a quote – see production offer.

Summary

Aluminum castings help build lighter, more economical vehicles – from the engine and suspension to the bodies and systems of electric cars. More about the technologies: permanent mold casting i high-pressure die casting.