2009-11-24 16:04:32 -
Provides fast, low cost launch of new wheel programmes
Alcoa solves the problem of how to launch multiple new wheel programmes quickly with no repeat capital investment.
In the current market crisis OEMs need to revitalise the appeal of their cars and prompt new car sales, but with minimal or no investment to help reduce costs. Adding new wheel programmes to a model range can often change the look and feel of the car and help improve the desirability of that car. Alcoa’s flexible manufacturing process can now offer car makers the opportunity to launch these new wheels, not only in a rapid time scale, but also at low cost.
Alcoa has refined a process that through variations in design, machining and finishing, generates an infinite variety of styles from a
single forged tool. Wheels using this process are amongst the strongest, lightest wheels available but with the structural integrity to meet the toughest fatigue requirements.
Additionally, Alcoa has advanced wheel finishing, including its patented Dura-Bright® surface treatment technology, allowing a wheel to be further differentiated not only by design and structure but also appearance and performance.
The base forging blanks are produced from billets of 6061-T6 aluminium, using the same metallurgy as the wheels Alcoa produces for the Boeing 747. An optimised forged wheel can be half the weight of a typical cast alloy wheel of the same diameter due to the superior material properties of these wheels.
“We can vary the wheel style and finish options widely, within a given forging envelope, without changing the base forging, resulting in many different styles with a single forged tool investment” says David Yates, Commercial Manager for Alcoa Auto Wheels Europe. “We are now using this principle widely for OEM customers in Europe and USA. Chrysler, for example, adopted this for the SRT family; wheels for the various models look quite distinctive yet share the same tooling. GM launched a range of wheels for limited edition models quickly, from a single tool investment and they have been very successful.”
As well as styling freedom, forged wheels provide a fast-to-market, cost-effective weight reduction; in particular, the lightweight rim sections reduce the rotational inertia of the wheel which improves the fuel efficiency of the car and reduces CO2 emissions. Lower wheel mass also means less work for the suspension; tyres remain in better contact with the road surface as lighter wheel assemblies are easier to control when hitting bumps; particularly important when cornering. This translates into improved grip, traction and braking, better vehicle control and a smoother ride.
Manufacturing also benefits, becoming leaner; apart from commonality of tooling, Alcoa’s approach results in reduced inventory and offers shorter lead times since the final machining is able to draw from a common stock of forged blanks. The machining process is cost-effective, requiring only 3-axis machines for most applications, though 5-axis capability is used for exotic designs such as the Lamborghini SV.
“Prestige brands such as Ferrari and Lamborghini already use our products, as do higher volume customers such as Audi and Chrysler,” concludes Yates. “The volume of enquiries is increasing rapidly because stylists like the design freedom; engineers like the light weight and accountants like the control of tooling costs.”
About Alcoa Wheel and Transportation Products
Alcoa Wheel and Transportation Products, headquartered in Cleveland, Ohio, serves the commercial vehicle, automotive, and defence markets with products used in a range of applications including cast and forged aluminium wheels, aluminium space frames, specialised vacuum die cast products, niche products such as Dura-Bright® and Dura-Flange® wheels and M-Series™ medium truck wheels, as well as a variety of other aluminium components for these markets. AWTP is composed of three divisions: Transportation Products, Commercial Vehicle Wheels, and Automotive Wheels. It employs around 2,800 people at 30 locations worldwide.
About Alcoa
Alcoa is the world leader in the production and management of primary aluminium, fabricated aluminium and alumina combined through its active and growing participation in all major aspects of the industry. Alcoa serves the aerospace, automotive, packaging, building and construction, commercial transportation and industrial markets, bringing design, engineering, production and other capabilities of Alcoa's businesses to customers. In addition to aluminium products and components including flat-rolled products, hard alloy extrusions, and forgings, Alcoa also markets Alcoa® wheels, fastening systems, precision and investment castings, structures and building systems. The Company has 97,000 employees in 34 countries and has been named one of the top most sustainable corporations in the world at the World Economic Forum in Davos, Switzerland. More information can be found at www.alcoa.com
Press Contact
Martyn Roberts
Market Engineering, North Bar House, Banbury, OX16 0TH, UK
Tel: +44 (0)1295 277 050
martyn.roberts@m-eng.com
Commercial Contact
David Yates
Alcoa Wheel Products, Hall Place Enterprise Centre, Church Hill, Harbledown
Canterbury, Kent, CT2 9AG
Tel: +44 (0)1227 452413
david.yates2@alcoa.com
High resolution images are available on www.autopresspoint.com
