One of the most popular casting processes for automotive castings is sand casting. This process uses molds and various alloys to create various auto parts. Sand casting is ideal for small to mid-sized part runs because the mold falls off at the end of the cycle and is easy to build quickly.

Aluminum alloys are popular in the sand casting process because they have a high strength-to-weight ratio and are much lighter than cast steel, zinc, brass, and iron. Aluminum castings are also more economical than welded parts or assemblies. Some of the advantages of using aluminum alloys over heavier metals include:

Excellent corrosion resistance.
Fewer cycle times.
Ability to anodize, polish, powder coat or electroplate aluminum.
Manufacturers often use sand casting for parts such as brake drums, intake manifolds, housings, engine parts and wheels in the automotive industry. Sand casting is ideal for engine parts that require precision machinability, pressure resistance, low weight and high strength. Aluminum motor castings offer many of these benefits, increasing manufacturing efficiency while improving the overall performance of the engine.

Several suspension components also use cast aluminum. Steering knuckles are cast in aluminum to allow for draft, radii and fillets. The knuckles are attached to the frame by control arms, which are also usually made of aluminum alloy.

Casting is also an efficient way to create durable, high-quality wheels for automobiles. The alloy wheel casting process involves one of two methods - gravity casting or pressure casting. Gravity casting uses gravity to fill the mold with molten alloy, while pressure casting typically uses injection or vacuum systems.