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Aluminum steering knuckles are widely employed for weight reduction and improvement of ride & handling performance. In this study, a high strength aluminum alloy for cast-forged knuckle was designed to achieve higher mechanical properties than those of the conventional foundry alloy. Using this alloy, high strength knuckles were manufactured and performed test of mechanical properties, suspension module strength and durability. The strength and the elongation of the developed knuckle were increased by 20% and 40%, respectively, as compared with the conventional alloy. Also this knuckle passed the static strength and durability test of the front suspension module.

High level vacuum die casting (HLVD) allows the casting products heat treatable with aid of minimized gas contents (e.g. max 1cc/100gAl), therefore it shows improved mechanical properties. In order to decrease the gas content of castings, vacuum level in cavity should be maintained under 5kPa during mold filling process. For the quality control of mass production, the practical inspection system should be required in the production process. In this study, we have focused on finding the relationship between process parameters and gas porosity, one of the main casting defects. We developed thin walled bracket with HLVD process to achieve weight reduction as well as cost saving. In addition, improved mechanical properties and productivity were acquired.