SMW Engineering in NewsUSA

2008-08-26

Imagine sitting behind the wheel and stepping on the gas as your vehicle of choice hugs the road and tops out at a speed of 185+ MPH. Exhiliarating. However, speed is not everything, and a car’s components must be designed, tested and redesigned over and over again to create a package that is nothing short of extraordinary. In today’s automotive industry, alloy wheels have become the de facto standard. Each year, nearly 60% of all new cars are fitted with OEM alloy wheels—translating into the production of millions of new cast alloy wheels annually. While cast alloy is a definite step forward from a steel wheel, the cast alloy wheel has its limitations, as the non-directional grain structure of a cast alloy and its structural porosity prevent any significant weight reduction. So, while cast alloy wheels are perfectly fine for your typical family sedan, they leave much to be desired for the true high-performance car enthusiast.

Wheel design is a challenging endeavor for ultra high-performance and exotic cars. Featuring exquisite design and refined shapes, these cars deliver the ultimate combination of aesthetics and technology—and drivers are willing to pay in excess of $150,000 for the ultimate feeling that comes with unparalleled speed, superior engine performance, and excellent driving dynamics.

The combined wheel, tire, and brake installations for any performance car are specifically engineered to reduce weight and squeeze out the last possible drop of performance from a vehicle - increase the weight and the handling of the car deteriorates, decrease it, and the car delivers increased steering precision, more comfort, and better performance. The outcome of many races is influenced as much by the power of the engine, as by the quality of the tires, dependability of the brake system, and—quite importantly--the lightness and the performance characteristics of the wheels.

In comparison to cast wheels, the production process for forged wheels is more complex. Also, the cost of producing a forged wheel is greater than that of a cast wheel because of higher specification and production expenses. However, this price difference becomes negligible when considering the significant weight savings and performance improvements the forged wheels produce when fitted on a performance car. The improvement goes beyond acceleration and deceleration: it extends to the full range of driving dynamics, including overall road holding and a more direct “feel” when cornering.

Indisputably, forged alloy wheels represent the cutting-edge in wheel design. While forged magnesium wheels are still regarded as very exotic and more appropriate for motorsport use, forged aluminium wheels are currently taking the market by storm. With the large number of performance and ultra high-performance cars sold annually, the demand for reduced-weight, forged wheels is increasing rapidly for both OEM and aftermarket wheels. The reason for this success is obvious: lightweight forged wheels provide better cornering, braking performance and acceleration. Additionally, due to the reduced un-sprung weight, the suspension is much more “direct” and will be less prone to vibrations.

Until recently, high-end automotive makers have been behind the curve in utilizing lightweight wheels on their production cars. Typically, a forged alloy wheel structure is about 40% stronger than its cast alloy counterpart, creating the opportunity for a 30% weight reduction in the wheel, and the use of magnesium instead of aluminium alloy further reduces wheel weight by 25%. While some manufacturers have been early-adopters of forged wheels—Aston Martin, Audi, BMW, Mercedes-Benz all have cars fitted with OEM forged wheels—others are just catching on, and the forged wheel market continues to grow rapidly.

As retail consumer interest in forged wheels continues to grow, a different marketing and sales strategy becomes necessary. Drivers of the Chevrolet Corvette, Maserati 4200GT or Ferrari 430 are quite versed in the technical details, so dealers and their staff must develop a more specialized approach for the sale of forged wheels. They need to be trained to know the product they promote and sell so that they are able to accurately inform, educate, and consult the buyer about wheel size and specifications, as well as of the correct tire size.

As SMW Engineering explains: "It remains difficult to understand why large model manufacturers do not yet fit all their performance-class vehicles with forged wheels. At last, we now have customers looking for an engineered product for their specific application. Not just style, PCD and backspace or offset. Some of these customers inquire about wheels with the lightest weight available for a specific car and with some choice of design. A few years back this was unheard of, as people would simply buy on style alone. They’d come into a shop, choose the wheel style they liked and drive off.”

Delivering superior vehicle performance, strength, durability, and aesthetic appeal, forged wheels clearly are one of the next key milestones in vehicle refinement and performance improvement across all segments of the automotive industry.

Belgium-based LIGHTEST, an affiliate of Magnesium.com, recently acquired a 40% stake in EAD-Europe (European Automotive Distribution), a leading designer and maker of upscale automotive wheels and other components. The result is the perfect marriage of the cutting-edge, high-tech metallurgy that LIGHTEST possesses as well as the impressive aesthetics and market knowledge that EAD is renowned for.

According to Mark Lisnyansky, a Board Member of LIGHTEST, the acquisition represents good synergy, “Each kilogram of the un-sprung weight removed through the use of the lightest materials available preserves the appealing looks and materializes in fuel savings and a smoother, more maneuverable ride. This improves safety while reducing greenhouse gas emissions, thus helping the environment. The EAD acquisition will help facilitate these very important developments and bring them to the market—and is exactly why the Board had approved this acquisition. Now our job is to educate the average consumer about what racers have known for many years”.