Manufacture of alloy wheels. Manufacture of light alloy wheels as one of the ways to generate income

What is the most important factor in wheel production? For us, the disc production process is a science and an art, add technical innovations and multi-stage quality control to it, and you will get a finished product from the YST Group.

Our production facilities are 4 modern full-cycle enterprises: 2 manufacturing plants alloy wheels with a total production capacity of 2 million/units per year and 2 stamped disc manufacturing plants with a capacity of 1.5 million/units per year. Each enterprise complies with the production standards ISO 14001:2004, ISO/TS 16949, ISO 9001:2008. All products have certificates of conformity with GOST-R50511, TSE, CE.

Our discs are developed and produced only by professional designers and technologists. The personnel selection system allows us to form a team of the best specialists and qualified experts.

Virtual tests

We know everything about each disc long before the first wheel ebbs. Each new model starts with a virtual mold simulation. Engineers develop a 3D model that is subjected to artificial tests. Our software allows you to predict in advance how the drive will behave in bench tests. After a positive result, an experimental batch is produced, which undergoes similar tests, but already in real conditions.

Manufacture of alloy wheels

The life cycle of each model begins with the casting of the mold. For the production of cast and stamped wheels in our factories, we use only high-quality raw materials. For the production of alloy wheels, we purchase raw materials only from trusted suppliers. The raw material supplier for stamped discs is the world-famous metallurgical giant Baosteel Group.

The main components of the alloy are liquid aluminum, silicon and alloying additives. In production, we use cast aluminum alloy in combination with heat treatment using T6 technology. It tolerates heat treatment better than others and withstands mechanical loads 20% better. When the alloy is ready, we send a prototype for spectral analysis for compliance with all technical standards.

When casting blanks, we use the low-pressure casting method and the mold casting technology. At the enterprises we have 25 semi-axle automatic installations low pressure and 20 die casting machines. In the process of casting, a rapid filling of the mold is achieved, the microstructure of the alloy is dense. Finished castings are submitted for fluoroscopic control to prevent the production of blanks with internal defects.

High-precision CNC machines allow us to cast and machine any wheel sizes from 12 to 30 inches. Also we can open any required mold according to customer's request.

The Italian painting line installed in both of our factories is one of the most modern. In production, we use environmentally friendly powder paints. When applied, the paint tends to be distributed evenly over the entire body of the disc, which improves the quality of the coating not only on flat surfaces, but also on sharp corners and edges of the product. This method of staining guarantees the uniformity of the coating, the absence of smudges, coating defects or the effect of "shagreen".

Due to the high strength of powder coatings, discs retain their presentation for a long time and are resistant to outdoor chemicals and mechanical damage.

Manufacture of stamped discs

In the manufacture of stamped discs, sheet steel is used, supplied to factories in coils. The coil is unwound and cut into blanks individually for each size. From each workpiece, a semi-finished product is made by rolling, pressing and welding, which is profiled and given the profile of the rim of the rim.

On the assembly line, the spokes are pressed into the rim and welded using the 4-stroke spot welding method in a carbon dioxide environment. The finished rim is checked for compliance with quality requirements and then a protective and decorative coating is applied to its surface.

Bench tests

Before leaving the assembly line, each disc is tested in its own certified laboratory: tensile test, radial runout and dynamic balancing, tightness, corrosion resistance, diagnostics for the integrity of the structure and the absence of microcracks, chromatic control and evaluation of the adhesive properties of the paintwork.

"YST Group" guarantees consumers impeccable quality and preservation of all consumer properties of each disc at the level of 99.3% throughout the entire service life.

As part of the import substitution program, YST Group has begun construction of a plant for the production of steel wheels under the Trebl brand. This brand has been presented on the Russian market since 2008. Affordable price, high quality and a wide range of standard sizes have made Trebl discs in demand among buyers from Russia. Currently, production is located at 2 plants in Asia, but in a year additional production facilities will be launched in Russia.

The future plant is a joint project of YST Group and its European and Chinese partners. It is intended to become the center for the production of stamped discs in Russia.

The plant will be located in Yaroslavl and form a developed industrial infrastructure around it. The production processes will have high level automation.

The enterprise will be equipped with modern equipment of Italian, American, Chinese and Russian production. The production capacity is 1.5 million wheels per year. The plant will produce 13, 14, 15, 16 and 17 inch wheels for all popular car brands. The new plant will allow reorienting commodity flows from China to Russia. Deliveries of finished products for original equipment (OEM) of vehicles at Russian manufacturing plants are already planned. Contracts for export of disks to Europe are concluded. All discs produced at the Russian plant will comply with the German TUV and Italian Qualilab standards.

A series of international quality standards ISO 9001 will be in force at the production site, and the reliability of finished products will comply with the standards adopted in Russia, North America, Europe and Asia. The social significance of the plant can be assessed today. Dozens of experienced engineers and specialists will be involved in the production. The plant put into operation will provide jobs for more than 150 people and will have a favorable impact on the socio-economic situation in the region.

In addition to the economic efficiency of production, we strive to achieve a balance with the environment. Especially for the new enterprise, a long-term program was developed to reduce pollutant emissions into the environment.

The new enterprise will introduce international standards and environmental monitoring systems, which will allow real-time regulation of the production load and not exceeding the maximum permissible standards for industrial emissions.

Cast horseshoes for a car horse

Choosing the best car rim is an infrequent procedure for an ordinary motorist. After buying a new car, we use the installed native disks for some time. But everything wears out and breaks, becomes obsolete or becomes unusable over time. The reason for choosing new wheels may be the desire to use a second set of wheels for winter or summer tires, so as not to do regular seasonal tire fitting. Or you want to change the design of your car horse, and replacing disks is just one of the most popular car tuning solutions.

According to the manufacturing technology, discs are divided into four types: stamped, cast, forged and prefabricated. The most common and affordable are stamped steel wheels. Forged and prefabricated wheels have a high cost, and therefore cannot achieve popularity among motorists. Alloy wheels are the golden mean in terms of price, design, and workmanship among all existing types. Due to its advantages over stamped discs, namely, lower weight and the ability to acquire any design forms, alloy wheels have become a desirable and fashionable attribute for any car. In addition to the fact that a car on alloy wheels looks sleeker and more attractive, it is more comfortable when moving, and the load on the car's suspension is less.

Alloy wheels are also popular among manufacturers. And therefore, there are so many of them on the market that it is extremely difficult for an ordinary motorist to choose the best from this many-sided range. We will present our rating of the best alloy wheel manufacturers that have settled on the Russian market.

Model

Price range, rub.*

a brief description of

Experts say that these are the most durable alloy wheels. In the manufacturing process, special varnishes are used to protect against reagents that are sprinkled on roads in winter.

An iconic Italian brand that has been a leader in the industry for over 40 years. A rich selection of models, various design solutions for every taste.

Size range from 13 to 20 inches, a huge range from classic to exclusive models. The products have an international quality certificate TUV.

The products of the German brand are aimed at lovers of an active, sporty driving style. The patented CPA (Ceramic Polished Acrylic) processing technology is used in the production.

High quality German wheels. At production of coatings for discs nanotechnology is applied. As a result, they acquire self-cleaning properties.

10 out of 10

Renowned Japanese company. Monitors all of its production bases. This achieves excellent production quality, both in factories in the USA and in factories, for example, in the Philippines. It is a supplier of OEM discs for such brands as: Toyota, Mitsubishi, Nissan, Suzuki, Ford, Subaru, Mazda.

All Replica alloy wheels are replicas of the original wheel models.

A Japanese company with extensive experience in the aviation industry, which has transferred its innovative developments to the process of manufacturing alloy wheels. The company's products have excellent performance characteristics.

Production is carried out at factories in China, Taiwan and Singapore. Almost 15 years in the industry market. Extensive the lineup, versatility of painting, low price made the wheels of this brand very popular in Russia.

Produced by a Taiwanese company for the Russian market. The range of sizes and modifications allows using these discs on almost all popular cars, from Lada to Porsche. The products have been certified by Rosstandart.

9.0 out of 10

SCAD alloy wheels have been produced at the plant in Divnogorsk, Krasnoyarsk Territory, for more than 10 years. The plant is considered one of the most high-tech in Russia. The plant produces more than two million discs a year. A wide range of models, high-quality performance and low price have made these discs in demand on the Russian market.

K&K discs are produced on German equipment from GIMA. The plant is located in Krasnoyarsk. It took 20 years for K&K to take a leading position in the Russian market. More than 1.5 million discs are produced annually in accordance with the standards and requirements of GOST

9.4 out of 10

* - “Price range” - means the price range for the model range presented in Russia

The best European manufacturers of alloy wheels

Alutec

Photo: www.autoshinavrn.ru

7 900 rubles.

The disks of the German company Alutec among experts are recognized as the most durable. In addition to having an international TUV certificate, the company's products successfully pass various tests, for example, for cyclic load according to the ZWARP method, an impact test with an excess of the design load by 60%, and others. The range of alloy wheels is diverse and will satisfy the requirements of any car enthusiast. There are also specially designed models for cars of auto giants such as Mercedes, BMW, Audi, Volkswagen. Even painting is offered summer and winter. In winter painting, a special paint and varnish coating is used, which increases the anti-corrosion properties and prevents the harmful effects of reagents.

Advantages:

• strength;
• very light;
• a wide range of;
• a large selection of sizes;
• durable paint finish.

Flaws:

• high price.

Reviews: “Real German quality. When you take an Alutec disc in your hands, you are surprised at its lightness. But at the same time it is very durable. No pits and potholes could crush, bend or split it, although there were different things. The tires flew apart, but at least something to the disk. The price is hefty, but these are the best alloy wheels, and true quality doesn't come cheap."

O.Z. Racing

Photo: www.autofelgen.ru

Average price for this model: 17,500 rubles.

Impeccable quality, elegant style, exclusive design, the latest technology, a wide range - all this allows the Italian company OZ Racing to stay at the top of the market alloy wheels. Its products are loved and respected not only by ordinary motorists all over the world, but also by Formula 1 racers, various rallies and sports.

Advantages:

• high quality materials;
• a light weight;
• great design;
• pits and bumps pass well;
• minimum damage;
• reliability.

Flaws:

• just a high price.

Reviews: “I bought myself OZ Racing Ultraleggera wheels. Pleased with the really light weight. My 15" rim weighs only 5.4kg. During use, I flew into the pits on our favorite roads more than once, but there are no dents or damage on the rims. The appearance is impressive. The car looks chic. "

AEZ

Photo: www.eurowheels.ru

Average price for this model: 13,000 rubles.

AEZ is part of the world famous German holding ALCAR. The use of high technologies, innovative developments, technological quality control have allowed this company to produce ultra-light alloy wheels for over twenty years. A million discs ranging in size from 13 to 20 inches annually roll off the assembly lines of the German giant. Design solutions are able to satisfy almost any motorist. But the main thing is the excellent quality of products, confirmed by the international quality certificate TUV - the German independent testing institute. The use of the patented Nano tec® technology allows AEZ discs to acquire an antistatic effect, which in turn helps the surface of the disc to self-clean from dirt and water.

Advantages:

• available ultra-light wheels under the marking "Lite tec®";
• anti-static coating that repels water and dirt;
• casting technology that ensures the uniformity of the metal structure without pores;
• strong discs;
• a wide range of models and sizes.

Flaws:

• price.

Reviews: "Disks are standing. Best rims The title is just a little confusing. The lacquer coating is so luminous even. Really repels dirt. The car itself is sometimes dirtier than the disks. They balance normally. At the tire fitting, there were no complaints about balancing. Look very stylish. Any passer-by pays attention and peers at the logo.”

Dotz

Photo: exshin.ru

Average price for this model: 11 900 rubles.

The products of the German company Dotz are aimed at lovers of an active driving style. The entire line is dominated by sports notes. For example, a popular model is specially designed for drifting fans. If you want discs with a glow effect, then the Dotz Touge Blaze is just for you. The whimsical design of the company's alloy wheels does not prevent them from possessing the most important criteria: strength and reliability. The CPA (Ceramic Polished Acrylic) processing technology has been introduced at the company's factories, the essence of which is grinding the disc with the smallest ceramic balls. The result is a smooth and shiny surface. Further, the products are covered with acrylic protection. Directly at the factories, DOTZ wheels are tested for strength. A specific feature of Dotz wheels is the use of different color stripes: yellow, green, orange and white, which adds an extra charm to the wheels.

Advantages:

• attractive, whimsical, exquisite design;
• strong, durable;
• a large selection of sizes;
• suitable for sports driving;
• the quality matches the price.

Flaws:

• big price.

Reviews: “I have truly German . I've never had a problem with them at the tire shop. I never had to roll it, although I have ridden them for three seasons. On our so-called roads, discs have repeatedly proved that they are the best, reliable and strong. But beware of fakes and don’t write nonsense later, riding Chinese.”

DEZENT

Photo: c-a.d-cd.net

Average price for this model: 4,000 rubles.

Dezent discs are known worldwide for their high quality, while the price for them does not go off scale. In the manufacture, nanotechnology is used, allowing products to acquire a self-cleaning effect. Dirt does not stick, but rolls off the surface. Dezent discs have shown themselves excellently during operation in the winter. More than 20 design modifications, size range from 14 to 22 inches, various decoration options. These discs have everything to make driving them prestigious, fashionable, and, most importantly, reliable.

Advantages:

• fair price;
• use in winter;
• practically do not require balancing;
• safety;
• durability.

Flaws:

• not found.

Reviews: “I ride discs. The disc is considered the flagship of the DEZENT line. The first thing that impressed me was the relatively low price. Even at first I doubted whether it was a fake. At the tire fitting they put it without any weights, they said that they did not require balancing. After 2 years of use the situation is the same. Didn't have to roll. The coating did not buckle, although I drove in the winter, and there are a dime a dozen of all kinds of chemistry on the roads. Light, high-quality, German wheels and at a normal price. Happy as an elephant."

Top Asian alloy wheel manufacturers

Enkei

Photo: www.elpokupka.ru

Average price for this model: 5,000 rubles.

Enkei is a Japanese company with a worldwide reputation. The company's production facilities are located in Japan, India, Vietnam, and the Philippines. According to the company's management, the quality of products does not depend on the country of manufacture, since the corporation has a monitoring program for all production bases. Cars of such brands as Toyota, Mitsubishi, Nissan come off the assembly line on Enkei wheels. The McLaren Mercedes Formula 1 team also uses Enkei Corporation wheels.

Advantages:

• good paintwork;
• strong;
• wide choice of design;
• well balanced.

Flaws:

• not heavy, but not very light;
• Our market is dominated by Chinese made.

Reviews: "Bought myself a model to Kalina. They stood up like family. They look chic. Balancing was not required. A well-known Japanese brand, although they seem to be made in China. In general, I recommend it."

Replica (Replay)

Photo: www.sibdomshin.ru

Average price for this model: 4 450 rubles.

For a long time, high-quality discs were produced under the Replica brand at factories in Turkey, Taiwan and even Italy. But due to the large number of fakes, the company rebranded trademark and now its products are released under the Replay logo. All discs of this company are exact copies of the original discs, with enough High Quality. The advantage of these disks is that they are easy to replace the original ones without overpaying and maintaining the car warranty.

Advantages:

• pass shock overload test and cyclic load test;
• exact copy the original, which allows the use of native bolts;
• as a rule, the replacement takes place without additional staging rings;
• the widest selection, easy selection by car
• reliable enough.

Flaws:

• and yet it is a copy.

Reviews: “Foolishly, I split one native disk intoPassat B7. When I found out the price for the original one, I was very upset. Surprisingly, the dealership manager himself recommended choosing a Replica, saying that this would not affect the warranty. I honestly didn't feel the change. Neither visually nor functionally. I go and already forgot that one disc is a copy of the original. The paint has not peeled off, there are no complaints about the disk at the tire shop.

Kosei

Photo: www.kosei-wheels.ru

Average price for this model: 5 050 rubles.

Since the beginning of the 50s, the Japanese company Kosei has been actively working in the aviation industry market. She was able to transfer the accumulated experience to the automotive industry when she started producing light alloy wheels. Japanese quality and reliability characterize the products of this company. Kosei alloy wheels and their high performance were appreciated by the Japanese automotive giant Totota, who took them into service with their cars from the assembly line. The ISO 9001 international quality certificate awarded to Kosei products once again confirms the durability, strength and safety of Kosei alloy wheels.

Advantages:

• ease;
• quality materials;
• sustainable paintwork;
• durable rim;
• easy centering;
• at a glance it can be confused with forged.

Flaws:

• complaints about the oxidation of the cover covering the bolts.

Average price for this model: 1 900 rubles.

IWheelz is a famous brand in the market car rims. And although it exists not so long ago, with its products it was able to win the sympathy of Russian motorists. The company's manufacturing facilities are located in China, Singapore and Taiwan. Models are made with guaranteed accuracy. And due to the range of standard sizes and design drawings, it allows you to install them on many cars.

Advantages:

• price-quality ratio;
• nice appearance;
• sufficiently strong and durable;
• many common sizes;
• according to the parameters correspond to the original.

Flaws:

• requires balancing;
• no fasteners included;
• unusual nuts with an internal hexagon.

Reviews: “I changed my stamped ones to cast Iwheelz Shark. Satisfied with both price and visual quality. Look stylish, unusual. Installed at the service station, so the troubles about nuts, fasteners, balancing did not touch me. After installation, the car behaved differently, the control became much easier. 7.5 thousand rubles for a set of 16-inch alloy wheels, a popular manufacturer. Frankly, I'm not happy."

LS Wheels

Photo: xn----8sbxheocaa7a7e7c.xn--p1ai

Average price for this model: 3 300 rubles.

A Taiwanese company whose products are mainly focused on the Russian market. Due to the variety of styles, good casting and painting quality, as well as affordable price, LS wheels are very popular among Russian motorists. LS Wheels products are certified by the German expert organization TUV.

Advantages:

• low price;
• high applicability to popular brands and models of cars;
• products are certified;
• huge selection of sizes.

Flaws:

• compared to top brands, the quality, alas, is not up to par;
• the price is a little high.

Average price for this model: 3 300 rubles.

The first Scud disc was cast in 2004 in the city of Divnogorsk, Krasnoyarsk Territory. Since then, the company has been able to become a priority supplier of Ford Motor and Volkswagen, increase the number of wheels produced to two million a year and arouse interest in its products not only among domestic consumers, but even among European ones. Scud disks have passed an independent examination by TUV, which allows and permits their operation in Western Europe and the USA. The design of Scud discs is like a classic, strict, restrained shoe without frills, but at the same time commanding respect. These are not the lightest, but they are strong enough to meet the current standards of the wheel.

Advantages:

• affordable price;
• reliability;
• strength;
• manufacturing quality;
• good balance;
• strict design.

Flaws:

• heavy compared to analogues;
• the metal is soft.

Reviews: “For a long time I suffered with the choice between KK and Scud. Couldn't decide at all. Helped by a friend who advised. Firstly, at a price they turned out to be cheaper than a similar Kika, and they were impressed by the reviews. Now my impressions and feelings: the design is beautiful, the size approached without problems, they balanced with a bang!, the discs are strong enough, the paint holds up well, I don’t see any damage. The ride became more enjoyable. For such a price, the best alloy wheels - I do not see any shortcomings.

K&K (KiK)



Photo: www.shinatut.ru

Average price for this model: 4 650 rubles.

K&K was founded in 1991 as a joint Russian-German enterprise at the facilities of the Krasnoyarsk Metallurgical Plant. The production of wheels from aluminum alloys. The low-pressure casting technology, which is widely used in the world, has allowed the increase in production, and now the range of K&K includes more than 60 designs and 400 sizes, and production volumes reach more than a million wheels a year. The production of original rims for the Volga and Gorky Automobile Plants has been launched. K&K products have passed state quality certification and are extremely popular with Russian consumers.

Advantages:

• when painting, SAM technology (smart molecules) is used to protect the disc from corrosion;
• 36 months warranty from the date of sale on the paintwork;
• Lifetime warranty on metal and wheel structure;
• the widest choice of design and standard size;
• highest applicability.

Flaws:

• there are complaints about the softness of the original OEM discs installed at car factories (Priora, Lada-Kalina).

Reviews: “I’ve been driving KiKa for 4 years, I didn’t notice any special problems. They hold a blow well and correspond to the declared load. Disc dealers claim that the probability of marriage with Kik is less than that of Scud, but they are close in quality. The paintwork seems to be normal, a couple of scratches just showed up, but it's not annoying.

Which alloy wheels are better to buy?

In addition to the best alloy wheel manufacturers described in the article, it is also worth paying attention to such brands as Italian MAK and Momo, German BBS, Enzo, Rial and Borbet, Japanese Yamato, American Vossen, ADV.1, HRE Wheels. When choosing a disc, it is worth considering that, despite the apparent strength of the structure, a cast disc, due to its granular structure, can accumulate microcracks invisible to the eye, which at a certain moment, or at peak load, can lead to cracking of the disc. Naturally, cheap non-certified disc models have a greater risk of splitting. Therefore, be careful when operating alloy wheels. In addition, pay attention to the fact that a disk on a store window and a disk on your car are completely different things, because the shape, body kit and color of your car ultimately affect its appearance. It is worth remembering and considering important characteristics rim: rim width and diameter, number and diameter of fixing holes, offset (ET), bolt length.

We hope this article will help you make the right choice.

Happy shopping!

We all know that alloy wheels are better than steel (stamped), also many of us know that forged wheels are better than cast ones. But not everyone knows how forged wheels are forged. Unfortunately, no anvils and bellows are used in this case ...

A small video digression, for informational purposes. Actually the whole process:

Now, let's read an article from Popular Mechanics magazine about how forged wheels are made.

We are standing in the forging and pressing shop of the Stupino Metallurgical Company, towering over us is a gigantic press that develops a force of 10,000 tons. A team of workers is changing the equipment of a stamping press, and Alexander Lovchev, deputy head of the production of car and motorcycle wheels at the Stupino Metallurgical Company (SMK), reveals the secrets of the production of forged wheels to us. “Actually, ‘forged’ is not entirely accurate from a technical point of view, it would be more correct to call them disks made by hot die forging in closed dies,” Alexander smiles. “But few people are able to pronounce such a complex name the first time, so the word ‘forged’ has taken root.”

“These discs are distant relatives of airplanes,” Alexander continues. - In the early 1990s, many enterprises that worked in the Soviet era for aviation and space, with unique equipment and technology, found themselves without government orders. And in order to survive, they were forced to switch to consumer goods. Someone began to make pans, and QMS - including wheel disks. The technologies used are truly aircraft-like - as in the production of some power elements of the glider structure. In this regard, Russian motorists are lucky: not all countries have such presses. And even where there is - such extremely expensive equipment, as a rule, works mainly for the aerospace (and not at all for the automotive) industry.

From casting to wheel

The foundry is the first stage of any metallurgical production

For disks, an AB-type alloy based on aluminum with alloying additives of magnesium, copper, copper, silicon and manganese is used. It is not only highly durable, but also plastic. Abroad, an analogue of this alloy is usually called "aviation aluminum 6061" (aircraft grade Al 6061). The finished casting - a cylinder with a diameter of about 20 cm - is cut into pieces of the desired length (depending on the size of the future wheels), put into baskets and sent to the forging and pressing shop.

Sector stamp. In hot forging, such stamps are used, consisting of several sectors. When the disk is finally formed, the upper part of the stamp is lowered and the sectors converge. At the same time, excess metal is squeezed out through the cracks, forming a flash

There, these blanks, while not even remotely resembling wheel rims, are heated up and, with the help of a press, they are “settled down” - flattened, turning into “pancakes” twenty centimeters thick and about half a meter in diameter. The process of further transformation into wheels occurs in several stages. First, the "pancakes" are heated to 430C and with the help of a preliminary stamp (heated to about 350C) they are turned into "pans" - preliminary blanks for automobile wheels.

After heat treatment, the wheels are waiting to be sent to the machining shop

The "pans" are again sent to the oven for heating, and then a special conveyor feeds them to the press with another set stamp - the final one. “The pause between the exit of the workpiece from the furnace and the actual stamping should not be more than 11 seconds, otherwise the workpiece will cool below the critical temperature,” Alexander explains. One of the workers lubricates the heated stamp with a special lubricant, the other two deftly grab the “pan” with long tongs and transfer it to the mold. The upper part of the press lowers, rises - and now the finished wheel is taken out from under the press, except for the flash (excess material squeezed out during stamping). The first four stamped wheels, after mastering the new stamp, go to the geometry control - only after that permission is given to use the stamp for mass production of disks.

Cylindrical rollers are the future wheels for motorsport

A press with a force of 10,000 tons (there are two of them in the SMK) makes it possible to produce large-diameter discs. “We are the only company in Russia that has mastered the production of discs with a diameter of up to 22 inches! Alexander says proudly. “You simply cannot push them through with less effort - you will have to heat the alloy to an almost liquid state, and this is no longer volumetric, but 'liquid stamping' - this is what we call high-pressure casting.”

Heat treatment and control

Despite the external resemblance that has already appeared, the mechanical properties of the wheels are still far from those wonderful qualities that forging is famous for. And it is famous for its high strength (it exceeds the strength of cast disks with a significantly lower mass), ductility (unlike cast disks, forged ones deform under high loads, and do not collapse) and elasticity (under moderate loads, they deform elastically).

To obtain all this, heat treatment is just what is needed. First, the wheels are hardened - they are evenly heated for several hours in an oven to 515C, and then they are quickly cooled by immersion in water. After hardening, the alloy already has the desired fine-grained-fiber structure, but in order for the wheels to acquire the desired mechanical properties, they need to be “aged” - wait until the structure is leveled and remove internal mechanical stresses. Under normal conditions, this can take a couple of months, but in order not to waste time, the blanks are artificially aged: they are kept in an oven at a temperature of 150-160C for about 12-14 hours, after which they are slowly cooled.

One of the workers with a brush lubricates the die tooling with a special lubricant so that the finished part does not stick to the mold

After heat treatment, at least 10% of blanks from each batch are subject to control. Their surface is etched: stamping defects and folds are clearly visible on a light etched surface. And one wheel from the batch is mercilessly sawn, cutting out a special fragment from it - the so-called template. The template is ground and etched, and then carefully examined in the laboratory for defects in deformation, heat treatment and alloy uniformity. “Most often, defects are found in the hub part,” Alexander explains. “The nature of deformations and thermal loads is the most complex there from a metallurgical point of view.” At this stage, the mechanical properties of the alloy are also controlled - the samples are fixed in a special tensile testing machine, which is used to determine the tensile strength, yield strength, relative elongation and hardness. If the defects and values ​​of the material characteristics do not fit into the tolerances, another wheel from the batch is examined. If the re-check also confirms these conclusions, then there has been a violation of the technological chain - and the entire batch is rejected. If all the parameters are normal, the batch of wheels goes to machining.

Made in Russia

From the workpiece, already reminiscent of the shape of the future wheel, to lathe the excess metal allowance is removed, a nipple hole is drilled in the rim, and mounting holes for the bolts are drilled in the hub part. The wheel is then placed on milling machine with CNC, which cuts out the programmed design.

Are there any design restrictions? In general, no - the pattern can be anything, the wheel can be made very light and openwork, and the only limitation is related to the load that it must withstand, - Alexander answers my question. – Here, for example, this 15-inch disk weighs a little more than 5 kg, almost two times less than the stamped steel counterpart. And at the same time, its parameters significantly exceed the requirements of the Russian GOST. By the way, this weight is not a record - at one time we made the lightest 15-inch wheel in the world for the Japanese market - it weighed 3950 g.

Practically finished wheel - all that remains is a locksmith and painting

“Some discs are additionally polished after machining. For M&K discs, which represent our premium segment, these operations are carried out abroad, - Alexander continues. - For the rest, the usual locksmith processing is carried out - sharp edges are removed, and then final control is carried out for compliance with the geometric dimensions of the drawing, rim runout and imbalance.

It is not necessary to control the last parameter according to GOST, but we do it, and our ‘internal’ standard in this respect is twice as strict as the Russian GOST. In general, the QMS has a very strict and well-established quality control system - the aviation past affects: at every stage, from castings to the finished wheel, parts are tracked by marking. See the number stamped on the wheel? After painting, final inspection and approval by the quality control department, the wheel is packed, and its factory passport will be kept with us for another ten years. How long does it take to produce a disc? About a week of pure time, but if you take into account the production schedule, it turns out to be about a month.

Russian technologies in the field of manufacturing forged wheels are quite recognized abroad as well. “Last year at the German ‘Motor Show’ in Essen, the main European annual exhibition in the field of car tuning, several tuning studios exhibited very expensive cars - Bentley and Aston Martin - on our M&K rims,” says Alexander. “Did the visitors know that these discs are Russian?” I ask. "Oh sure! We are not shy about the 'Made in Russia' stamp. We are proud of him."

By the way, there are quite a few manufacturers of forged wheels in Russia, but they have one big drawback, which is explained by the economic component. This disadvantage is the design, or rather its almost complete absence.

Look at VSMPO disks, good rims, but the design is highly amateurish.

Look at Slik - very few designs...

And this is the situation with almost all forging manufacturers.

› Disks to disks are different ...

STAMPED STEEL WHEELS
The most widely used are stamped steel discs. Structurally, they consist of the disk itself (plate) and the rim. The disk (plate) is stamped from sheet steel according to a special profile to increase rigidity. The wheel rim is also stamped from steel. Both components are interconnected by spot welding. After that, a protective coating (enamel, powder coating ...) is applied to the surface.
Advantages of steel stamping
Steel rims are fitted to most of the cars that roll off assembly lines around the world. The secret of such popularity, as always, is trivial, and lies in their cheapness and ease of manufacture. But the advantages of stamped discs do not end there: even with a very strong impact, they do not collapse, but crumple, which improves the safety of the vehicle, not to mention the possibility of recovering a deformed wheel. In addition, let's remember physics, namely the fact that a certain amount of energy must be expended to deform any material. So, if a shock load acts on a car wheel, then the steel plastic disk, deforming, takes on a significant part of the impact energy, while the suspension and steering parts receive minimal damage.
Cons of steel stamping
Outwardly, such discs do not pretend to be original at all, so they are covered with special caps. Of course, if the car is working and is used to transport goods to hard-to-reach areas, these wheels are for it. But, if you have a beautiful car that serves you not only as a vehicle, but also strengthens your image, steel stamping will spoil everything. The main disadvantage of a steel disc is its relatively large weight, which adversely affects the performance of the car. To reduce the weight, it is necessary to reduce the thickness of the disk walls, which is unacceptable due to the condition of maintaining sufficient resistance to deformation (i.e., according to the strength condition). Another disadvantage is the poor resistance of the disc material to corrosion, which progresses rapidly with the destruction of the protective coating.

FORGED WHEELS
The second method of production of alloy wheels is forging, or, as experts say, hot forging. Therefore, forged wheels are often called stamped (not to be confused with stamped steel).
pros forged wheels:
During forging, strength is achieved higher than during casting, since the grains are crushed, deformed and stretched in the right direction - as a result, the metal structure becomes fibrous. Due to this, it is possible to reduce the wall thickness of the forged disc by about 20% compared to the cast one. The high strength of the material of the disks provides them with good weight characteristics: the mass of a forged disk is 30-50% less than the mass of a steel one and 20-30% of a similar cast one. Due to the high ductility, such a disk does not collapse after a strong impact, but deforms like a steel one. Stamped magnesium wheels have good corrosion resistance, while aluminum wheels can be used without paintwork at all. All in all, forged disc absorbed all the advantages of cast and stamped steel counterparts, while getting rid of their shortcomings.
Cons of forged wheels:
A significant disadvantage is the very low material utilization rate of 30-40%, which significantly increases the cost of the product.
Forged wheel production technology:
The initial billet is heated to a temperature at which the alloy acquires the highest plasticity (about 400-470 ° C), then the heated ingot is pressed into a special shape under the action of a press, and the output is a kind of wheel - a forging. Disks produced by this method may or may not undergo heat treatment. Everything is determined by the composition of the alloy. Often, the mechanical characteristics of discs that have undergone heat treatment, and without it, made from different alloys, practically do not differ. If heat treatment is carried out, then it includes hardening followed by aging. After the forging is sent for machining, then decorative coatings are applied. This manufacturing technology makes it possible to obtain discs whose material has a strength comparable to steel, and ductility is only 20-30% lower. In the production of forged wheels, alloys based on aluminum and magnesium are widely used.

CAST WHEELS
Alloy wheels are divided depending on the manufacturing process into cast and forged. Depending on the materials used - aluminum and magnesium. Although, at one time, there were attempts to make discs from titanium alloys. The latter are characterized by high strength, good ductility combined with high corrosion resistance. However, due to the complexity in production and the high price, titanium discs have not been widely used. The vast majority of alloy wheels (approximately 95%) are made by casting.
Advantages of alloy wheels:
The main advantage of this method lies in the high material utilization rate, which reduces the cost of production and is the determining factor in pricing. The lightness of alloys is their main advantage, since in this case the mass of unsprung parts of the car is reduced. Because of this, when driving over bumps in the road, less shock loads act on the body, which means that such an operational property of the car as smoothness improves. At the same time, the working conditions of the suspension are also improved: elastic and damping elements perceive less loads, thereby increasing their service life. Lightweight wheels quickly restore contact with the road surface when hitting an obstacle, which increases the stability and controllability of the car at high speeds. Reducing wheel mass has a positive effect on vehicle dynamics, as less force is needed to accelerate and brake a less inertia wheel, which ultimately leads to longer engine, transmission and brake life, as well as reduced fuel consumption. In general, light weight is a serious advantage of cast aluminum wheels, but not the only one. A significant advantage of such discs is also their attractive appearance and variety of design options. Some companies present on the market today more than 100 designs of alloy wheels for any type of car.
Cons of alloy wheels:
A significant disadvantage is the production of a casting, the metal of which has a free non-directional crystal structure, which reduces the strength of the disk. Therefore, to maintain the strength characteristics of the disk, the thickness of its walls has to be increased. Due to high quality requirements for products, not all casting methods can be used in the production of rims. The main methods here are casting under low pressure or with counter pressure. These methods provide increased strength characteristics in the manufacture of three-dimensional thin-walled parts.
Alloy wheel production technology:
The molten alloy is poured into special molds, where it cools, then the resulting blanks undergo heat treatment. It includes heating the casting above the phase transformation temperature (500-550 °C), holding at this temperature, followed by fairly rapid cooling in an aqueous medium. As a result of hardening, a structurally unstable state of the alloy is obtained. To bring the alloy closer to structural equilibrium, the castings undergo an artificial aging process, which consists in heating them below the phase transformation temperature (150-220 °C) and holding at this temperature for some time (3-9 hours) followed by cooling in air. At the next stage of production, castings are machined, then protective coatings are applied. The strength of cast alloys, as well as their ductility, after such processing is less than that of conventional structural steel. Moreover, if the strength is lower by 30-40%, then the plasticity is 4-5 times lower.