Development of a Forged-Equivalent Aluminum Wheel with the Mubea Cast Forging (MCF) Method

Traditional manufacturing methods for aluminum alloy wheels have either high tool costs (forging) but good properties or lower properties, which result in higher weight (LPDC). For that reason, the Mubea Cast Forging is introduced as innovation that combines the superior material and wheel properties of forging with the design flexibility of casting. The patented casting process with two squeezing steps is described as well as the shortened heat treatment and sophisticated quenching. It is demonstrated that a fine-grained, porosity-free microstructure can be produced. The high material and fatigue properties are discussed and compared to the traditional methods using the example of a 20-inch AUDI wheel, originally designed for forging.