Casting aluminum wheels is the most common manufacturing process for alloy wheels on the market. How these wheels are made is molten aluminum is poured (or drawn in with a vacuum) into a mold which forms the material into the desired wheel shape. The aluminum cools and then it is machined, drilled and trimmed into the final wheel. This processing of casting a wheel is easy and less expensive than other methods however the process of allowing the molten aluminum to solidify can lead to porosity. Porosity is inconsistencies in the material structure which can lead to cracking and the overall reduction in the wheel’s integrity. Because of porosity, in order to ensure a cast wheel can be stronger manufacturers have to use more material which leads to heavier wheels.
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