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By changing the method of manufacturing cross members (overall length : 1300 mm) for passenger vehicles from a welded steel plate structure to an integrated cast aluminum structure, the number of components required has been cut from 16 to 3, and the weight has been cut by half, from 20 to 10 kg. The casting method used is squeeze casting, which imparts excellent mechanical properties and permits casting of large-size products with thicknesses generally as low as 4.5 mm.

This paper deals with the newly developed technique of the squeeze casting process by using a horizontal die casting machine. Mechanical properties of squeeze castings are superior to those of gravity die casting. The productivity is attainable as high as the pressure die casting by employing the horizontal type of die casting machine for the squeeze casting process. We found also that 0.4∼0.6% Mg addition to A356 alloy improved the squeeze casting performance and that it led to higher tensile strength. The process has been put into practical use to fabricate disc brake calipers, gear pump casings, brake pedals and so on commercially.