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Recent years have seen a spurt in the demand for pick up trucks and sport utility vehicles (SUVs). Over a thirty percent jump in demand is expected in the next five years for the domestic and the transplant SUVs combined. The ratio of trucks to passenger cars on the road will be adversely affected in the near future by this growing demand. This shift of balance may compel an extension of CAFÉ to these classes of vehicles in the next few years. The differential carrier, one of the heaviest components in the drive train, is an excellent candidate for conversion into aluminum from iron. The potential weight saving is nearly fifty percent. The objective of this paper is to detail the successful development of an aluminum carrier to replace traditional ductile iron carriers.

Aluminum castings have been replacing iron castings and steel fabrications with significant weight savings. Casting designers face the challenges of selecting the casting process best suited for the casting configuration and selecting the alloy most suited to meet the part function. Casting processes currently proven and applicable to high integrity aluminum castings are briefly described. The available alloys are listed along with their properties. General guidelines are offered for the selection of casting processes and alloys. The scope for further work is defined. The emerging technologies to be harnessed are identified.

An overview of emerging casting processes is presented. The scope that these processes offer to designers for creative designs, superior product performance, closer dimensional control, and reduced cost is outlined. Exposure to these developments, it is hoped, will motivate the designers to explore these processes for innovative designs.