How are alloy wheels made

One-and two-piece alloy wheels
One-piece alloy wheels are mainly produced by low -pressure die casting with subsequent machining. Because of the relatively porous grain structure a given minimum wall thickness must be maintained in order to guarantee adequate mechanical strength.

For this reason, cast alloy wheels carry hardly any weight benefit over conventional steel wheels. Whereas in the past styling was a major factor in favour of alloy wheels, weight considerations are today becoming increasingly important. In recent years, the use of Leico flow forming technology has successfully met both requirements. The latest developments with the goal of still further weight reduction include, for example, a full-face wheel with formed undercut yielding up to 25% reduction against a conventional cast wheel.

In the case of a two-piece wheel, the centre serves as a carrier for the styling effects in the form of either a casting or forging. The tyre-bearing rim is flow formed and an internal web for attaching the centre is integral with the cast blank.

An alternative is a flow formed rim made from rolled aluminium strip. The spider is attached by welding and comprises of a pressing which has been spun and flow formed in the region of the horn.