Aluminum Die Casting Casting Process Revolutionizes Aluminum Wheels

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Albert Handtmann Metallgusswerk GmbH & Co. KG

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Albert Handtmann has further developed casting processes within the die-casting method, enabling the production of complete aluminum wheels for the first time. The new light-performance wheels weigh up to 20 percent less than conventional low-pressure cast wheels.

The new casting system enables the production of aluminum wheels using the die-casting process for the first time. In this process, the wheel blank is cast in series at Handtmann using the die-casting method. Subsequent processes, such as machining, painting, and all quality assurance processes, take place at the partner company Cevher Group. "With the introduction of this technology, we are opening the product field of automotive wheels to die-casting and at the same time creating the basis for transferring the process to other components in the future. This sets new standards in the light metal and automotive industries," says Dirk Seckler, Co-CEO of Handtmann Leichtmetallguss.

HPDC As A Key Technology for Efficient Wheel Production

The heart of the casting process is the high-pressure die-casting (HPDC) method, which has proven effective for the efficient production of large series. Handtmann is using this high-performance die-casting technology for the first time to manufacture complete aluminum wheels, a product segment previously reserved exclusively for the low-pressure casting process.

In HPDC, liquid aluminum is injected into a precisely designed mold under very high pressure in a very short time and solidifies under applied pressure. This method enables the production of complex, thin-walled components with high dimensional accuracy and excellent surface quality in large quantities. The combination of short filling time, high clamping force, and automated processes allows for efficient series production. The components are produced almost in their final contour, reducing the need for machining. For Handtmann, HPDC forms the basis for highly productive mass production of structurally relevant aluminum components, such as wheels. At the same time, the process supports OEMs and wheel manufacturers in reducing CO₂ emissions and developing aerodynamically optimized designs.

Thanks to the new design freedom in HPDC and minimal distortion in die casting, designs can be implemented that were not achievable with traditional methods. This will excite car enthusiasts and designers alike. Additionally, the often extra aero cover is no longer needed, further reducing weight and costs.

Andreas Würzer

For automotive manufacturers and wheel producers, CO₂ reduction in both vehicle production and operation is a top priority. The new die-cast wheel meets these requirements by reducing air resistance due to its lower weight and aerodynamically optimized geometries, thereby increasing the range, especially for electric vehicles. "Thanks to the new design freedom in HPDC and the minimal distortion in die-casting, designs can be realized that were not possible with traditional methods. This will excite car enthusiasts as well as designers. Additionally, the often additional aero cover is no longer needed, which further reduces weight and costs," says Andreas Würzer, Head of Technical Development.

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Driving Performance Noticeably Improved

End customers benefit from a light-performance wheel that noticeably improves driving behavior due to reduced unsprung mass. The combination of attractive design, enhanced driving dynamics, and sustainable production increases the overall performance of the vehicle. Fleet operators, such as those in logistics, car-sharing, or corporate mobility, also benefit in terms of efficiency and cost reduction from the optimization effects. The improved CO₂ balance can also be used for certificates and sustainability reports during operation, thanks to reduced fuel or energy consumption.

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