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Casting Source Magazine
  • Current Issue
  • Industry News
  • Archives
  • Casting Source Directory
  • Photo Galleries
  • Columns
  • Advertising
  • Subscribe
  • Casting Competition
  • Metalcaster Prospectus
  • eNewsletter Archives
  • Modern Casting Magazine
  • Event Calendar
  • Foundry Video Central

3 Ways Vehicles Are Reducing Weight

Chevy Bolt

Electric Vehicles

Electric vehicles, like the Chevy Bolt, use materials such as aluminum, magnesium and carbon fiber to drive down curb weight.
Mirror Reinforcement

Vacuum Diecasting Replaces Steel Stamping

Part Count Reduction: 5 pieces to 1.
Weight reduction: 20% mass savings.
• Vacuum diecasting creates high quality parts with high structural integrity.
• The aluminum casting design gave engineers flexibility to design more efficient attachment points.
• Smart tooling design helped the supplier make more parts per cycle.
lower control arm

Ductile Iron Replacing Aluminum

Part Count Reduction: Same.
Weight reduction: 6 lbs.
• Hollow design helped reduce mass.
• The ductile iron alloy chosen offers high ductility and toughness so thinner walls could be used.
• Casting solidification simulation ensured a smooth and rapid setup for production.
Side Door

Steel Stamping to Magnesium Casting

Part Count Reduction: 7 parts to 2.
Weight reduction: 19.4 lbs.
• Elimination of spot welding.
• Strengthening ribs for required stiffness with less overall mass.
• Fluidity of magnesium made casting thin sections possible.
• Tool designed with internal heating and cooling to aid solidification.

Ford and General Motors worked with their casting suppliers to reduce vehicle weight with a variety of methods, from replacing material to switching processes.

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