PCPC™
Pressure-Counter-Pressure Casting (PCPC™) is the first application of our new advanced casting technology for automotive steering component manufacturing. It was developed for the production of automotive structural components such as suspension steering knuckles.

Historically, cast ductile iron and forged steel have been materials of choice for these types of components since high strength and ductility were an absolute necessity. Now, PCPC™ can provide these properties with low-cost, lightweight aluminum castings.

Overcoming cost and performance limitations
Traditional light-metal (aluminum, magnesium) casting/molding processes, such as hot- and cold-chamber die casting, and other aluminum structural casting processes (low-pressure, vacuum and squeeze casting) have limitations in performance and manufacturing cost. These performance limitations are caused by number of manufacturing shortcomings, including non-uniform and turbulent metal flow, entrapment of gases during mold filling, and impurities during metal cooling and solidification.

PCPC™ uses a combination of pressure and counter pressure to control mold filling.

This ensures:

• True metal-flow uniformity
• The prevention of gas entry into the metal
• Directional and uniform solidification
• Outstanding strength and ductility

Benefits:

• Using PCPC™ reduces costs, increases productivity and yields superior performance characteristics.
• Provides customer with 50% weight savings over conventional iron knuckles while maintaining critical safety and performance characteristics.
• Allows automakers to design more car-like ride and handling into light trucks and SUVs.
• Addresses automakers search for fuel-efficiency
• Demonstrates INTERMET's leadership role in metallurgical and process technology.