A casting AlSiMg-based aluminum alloy comprising by mass 12.0-14.0% of Si, 1.5-4.0% of Mg, and 0.10% or less of Mn, the balance being Al and inevitable impurities, and having excellent specific rigidity, strength and ductility, and its cast member.

Described herein is a trumpet arm for use in an electric drive axle. In one embodiment, the trumpet arm comprises a housing with an arm section extending an arm length, the arm section having an outlet at a first end, and a flange with a planar face at a second end opposite the first end. The trumpet arm further comprises internal buttresses positioned in an interior of the housing and extending through at least a first portion of a flange length of the flange, a flange/arm transition at which the flange transitions into the arm section, and at least a portion of the arm length.

The present application discloses an air suspension system, including a frame for mounting a vehicle body, a bridge housing for mounting wheels, and air springs, shock absorbers, a connecting rod frame and a thrust module connected between the frame and the bridge housing. Since the thrust module is standardized, a suitable thrust module can be matched according to different working conditions, thereby making the complex suspension adjustment work lightweight.

A method for manufacturing a vehicle wheel includes: a casting process of manufacturing the wheel in a one-piece body having a forming end and a temporary flange protruding at inner and outer sides of the wheel, respectively, wherein the one-piece body further includes a resonance chamber forming groove; a primary shape machining process of forming a stepped part at an outer circumferential side of the resonance chamber forming groove; a flow forming process of bending the forming end to be seated on the stepped part; a friction stir welding process of integrally bonding a portion where the forming end and the stepped part are in close contact with each other; a fine machining process of removing the temporary flange; and a sound-absorbing hole machining process of forming a sound-absorbing hole for communicating between the resonance chamber and an interior space of a tire in the forming end.

Provided discloses an integrated axle assembly and structural assembly. The integrated axle assembly comprises an axle tube assembly extending in a first direction; a front support arm extending circumferentially from the axle tube assembly in a second direction perpendicular to the first direction for attachment to the frame; a rear support arm extending circumferentially from the axle tube assembly in a third direction away from the second direction for mounting a resilient assembly; and a brake base plate extending in a peripheral direction from the circumference of the axle tube assembly; the axle tube assembly, front bracket arm, rear bracket arm and brake base plate are molded in one piece, which improves the assembly efficiency.

A method for casting an aluminum wheel comprises preparing a melt having a predetermined chemistry and including silicon in a range from 8.5 to 10% mass and aluminum; degassing and refining the melt; adding a grain refiner including aluminum-titanium-vanadium-boron (AlTiVB) and a master alloy to the melt; and casting the aluminum wheel.

An idler wheel includes a hub, an outer rim, and a pair of side plates that form an interior cavity extending radially between the outer rim (110) and the hub, and axially between the pair of side plates. The first side plate defines a maximum side plate axial thickness disposed radially next to the hub in a cross-sectional plane containing a radial direction, and an axis of rotation, as well as a minimum side plate thickness disposed radially next to the outer rim. A ratio of the maximum thickness to the minimum thickness ranges from 1.325 to 1.900.

A vehicle axle carrier having a one piece aluminum body produced by a low pressure die casting process and which integrates each of a differential housing, axle tubes, and attachment points for each of wheels/hubs, suspension struts, control links, jounce bumpers and electrical harnessing or brake line connections. Localized areas of the body, including the axle tubes exhibit varying thicknesses in order to compensate for the mechanical properties of aluminum. The low pressure die casting process accounts for each of die pull direction, draft angles and minimal wall thicknesses, with the aluminum body produced combining the features of lighter weight and infinite recyclability.

Described herein is a trumpet arm for use in an electric drive axle. In one embodiment, the trumpet arm comprises a housing with an arm section extending an arm length, the arm section having an outlet at a first end, and a flange with a planar face at a second end opposite the first end. The trumpet arm further comprises internal buttresses positioned in an interior of the housing and extending through at least a first portion of a flange length of the flange, a flange/arm transition at which the flange transitions into the arm section, and at least a portion of the arm length.

A method of manufacturing a cast vehicle wheel including a wheel trim cover attached thereto. A removable first tool insert is installed into a mold assembly. The tool insert includes a mounting feature that communicates with a cavity of the mold assembly to form a mating feature in the wheel. A wheel trim cover is provided and is attached to the wheel at the mating feature via a coupler formed in the wheel trim cover such that the relative position of the coupler and the mating feature positions the wheel trim cover relative to the wheel in a first predetermined position. After casting, the positional dimensions of the mating feature of the wheel relative to the coupler of the wheel trim cover is evaluated to determine the positional accuracy of the mounting feature of the first tool insert. If necessary, secondary inserts with improved mating features are provided and exchanged.