This is exactly where the innovative ‘aluminium-to-iron’ strategy from GF Casting Solutions comes in: the switch from aluminium alloy casting to ductile iron casting for automotive steering knuckles opens up completely new perspectives. International OEMs have already successfully tested the concept, the first applications are in use in series-production vehicles with alternative drive systems – and the solution is now in mass production.
Innovation with added value: the ‘aluminium-to-iron’ solution
GF Casting Solutions responded to the industry's weaknesses and developed a concept that replaces aluminium casting with ductile iron casting – without compromising performance. The result is an economical, reliable and sustainable steering knuckle that offers several advantages:
1. High cost-effectiveness
Although cast iron steering knuckles are around 10–20% heavier than their cast aluminium counterparts under the same load, costs can be reduced by up to 30%. This advantage is a strong argument, especially in the field of alternative drive systems, where reducing vehicle costs is a decisive factor.
2. Impressive performance
Thanks to bionic design, topology optimisation and state-of-the-art development processes, the cast iron steering knuckle has been specifically designed for efficiency. Extensive testing under a wide range of operating conditions proves that the components are stable, durable and meet the highest requirements.
3. Lightweight construction through intelligent design
GF Casting Solutions also takes a smart approach to weight. This has resulted in the development of a ductile iron steering knuckle that saves around 26% in weight through functional integration, combining the advantages of cost reduction and performance.
Impulses for the mobility of the future
With its ‘aluminium-to-iron’ solution, GF Casting Solutions proves that innovation does not necessarily have to be more expensive. Instead, the company provides an answer to the industry's crucial question: How can the requirements for lightweight construction and cost control be effectively combined?
Given its increasing use in various vehicle models, the solution is likely to have a significant impact not only on steering knuckle technology, but also on the entire development of components for vehicles with alternative drive systems – taking the industry to a new level.
