Use of highly styled aluminum wheels and aluminum castings for various chassis components has dramatically increased in the O.E. community due to the styling and weight reduction opportunities afforded. The processes historically considered for aluminum chassis components have been forgings, permanent mold castings (low pressure and gravity) and occasionally high pressure die castings. The advent of the Pore-Free process in the United States affords the design engineer a new technology that combines the benifits of high strength, ability to heat treat, absence of gas porosity, weldability and a high degree of dimensional accuracy in a single process. Basic work over the past two years has resulted in a U.S. talent-based Pore-Free die casting process capable of producing high elongation, high ultimate and yield strength, hydrostatically sound and dimensionally precise castings suitable for styled wheels, various stressed chassis components and pressurized vessels such as power steering gear housings and pump bodies - all at comparable or lower cost than with current production methods.