Intermet begins PCPC production of new steering knuckle, announces $400 million in new business. (North America).

Intermet Corp., Troy, Michigan, announced it began producing an innovative aluminum steering knuckle for a new high-volume light vehicle.

Using the aluminum pressure-counter-pressure casting (PCPC) process that it developed, the firm began supplying knuckles in production volumes in October. Intermet expects the aluminum knuckle market to grow as the use of lightweight suspensions increases and because automakers are designing better ride and handling into minivans, pickups and sport utility vehicles (SUVs).

The value of the contract is expected to be $22-$25 million annually through the vehicle platform lifecycle. PCPC manufacturing cells were installed at the firm's Stevensville, Michigan plant, where the knuckles are cast and 100% X-rayed. A separate $30-million PCPC program for SUV front knuckles was also recently awarded to the firm.

According to Gary F. Ruff, executive vice president of technical services, the firm is working on a number of other aluminum safety- and structural-component programs for automakers via advanced diecasting techniques and recently implemented semisolid casting.

In other news, Intermet announced in January that it received $400 million in new business in 2001. The new contracts, which include components for powertrain, chassis/suspension and interior applications, are for programs slated to run through 2006.

Beyond knuckles, new aluminum programs include ABS housings, tensioner arms, engine front and valve covers, and heat sink and electronic housing programs. Significant new magnesium work was secured for instrument panel frames, valve covers and steering wheel tilt mechanisms. Ductile iron programs include knuckles, tie rods and control arms for car, light truck and SUV applications. A new austempered ductile iron torsion bar adjuster concept also has been developed.