Providing consumers a more car-like ride and handling in pickup trucks, SUVs, and minivans has often put auto designers at odds with the idea of taking weight out of the vehicle in order to achieve better mileage. A new high-tech, aluminum steering knuckle, introduced by INTERMET Corporation (Nasdaq:INMT), one of the world's leading independent manufacturers of cast-metal automotive components, is solving this dilemma.
Using an innovative aluminum casting process called pressure-counter-pressure casting (PCPC (TM) ), INTERMET engineers have been able to duplicate the strength and ductility of heavy cast-iron or forged-steel chassis components, providing a 50-percent weight savings while maintaining critical safety and performance characteristics.
Traditional light-metal casting and molding processes sometimes have turbulent and non-uniform metal flows that create limitations in performance and manufacturing cost for certain applications. PCPC controls how molten aluminum fills a casting mold to ensure uniform metal flow, and it prevents the entrance of gases (a leading cause of porosity in the metal). This results in outstanding strength and ductility for automotive structural components, which ultimately contributes to vehicle fuel efficiency.
Said INTERMET CEO Gary Ruff, "Prior to PCPC technology, in order to provide heavier vehicles with a car-like ride and handling, automakers would have to beef up their suspensions . . . resulting in packaging issues and additional vehicle weight. PCPC provides a real solution to these issues, without sacrificing strength, ride or safety."
To date, PCPC aluminum steering knuckles are found on Chevrolet Venture, Oldsmobile Silhouette and Pontiac Montana minivans and a whole host of GM mid-sized cars. And DaimlerChrysler recently tapped INTERMET to supply PCPC steering knuckles for its new Dodge Durango.
Ruff added that the company is working on a number of other aluminum safety and structural component programs for automakers using advanced casting techniques, in addition to PCPC. "We are committed to providing innovative solutions that meet customer needs. We must be doing something right - INTERMET parts are on every one of the top 30 selling vehicles in the U.S."
