In each aluminum structural casting process, inherent limitations are exhibited either in performance or manufacturing cost. These processes include well documented technologies, such as low pressure, vacuum-assisted casting, combinations of low pressure and vacuum, and squeeze casting. In most cases, performance is hindered by non-uniform metal flow, entrainment of gases during the mold filling process, or segregation of impurities during solidification.
The development of the pressure counter pressure casting process eliminates these deficiencies by controlling mold fill to insure true metal flow uniformity, preventing the entrance of gases during filling and providing for both directional and uniform solidification. This results in outstanding strength and ductility for components, such as steering knuckles, produced by the PCPC process.
Developments in Lightweight Aluminum Alloys for Automotive Applications: 2001-2005-PT-130, Automotive Casting Processes and Materials-SP-1603, SAE 2001 Transactions Journal of Materials & Manufacturing-V110-5