Forged, not cast - The Process

Forged, not cast - The Process

Forged aluminium wheels - made by OTTO FUCHS – combine visible beauty and invisible safety.

The superior properties of forged alloy wheels as compared to cast ones result from the applied material.

The OTTO FUCHS forging material, a forging alloy with at least 95% aluminium, is far superior to any cast material with respect to strength and ductility. Reduced wall-thickness and weight reduction are the result of the combination of best materials and most modern manufacturing and simulation techniques. Not least: In extreme driving situations the forged aluminium wheels offer greater safety margins than cast wheels.

Another important advantage of forged alloys is the feasibility of polishing: the dense microstructure without porosity and the low silicon content are not only responsible for the superior mechanical properties but also allow for high gloss polish of the wheel surface. Also in this regard forged wheels are setting the standards!

From a high performance material in combination with highly developed calculation- and simulation software, modern manufacturing technology and decades of experience together with high graded craftsmanship, result exclusive masterpieces of forging technology.

By their low weight forged wheels effectively support the car manufacturer targets of reduction of weight, energy consumption and carbon emission. Their sophisticated styling as well as the exclusive surface appearance considerably contributes to the desirability of the whole vehicle.


The Forging Process

Forging – a complex process, which must provide the maximum in safety. In a series of steps, the wheel is prepared for its important task for a long automotive life.

Step 1: The cast bar

A cast block also produced by OTTO FUCHS of over 6 m in length is the starting material from which a blank is sawn off, exactly matching the later wheel.

Step 2: The pre-forging

In the first forging stage, the blank is forged into a rotationally symmetric piece under a force of 4,000 tonnes.

Step 3: The styling forging

In the second forming stage, the styling is pressed into the pre-forged blank in a 7,000 tonnes press, which largely gives the wheel its later appearance.

Step 4: The perforation

In the last forging stage with 800 tonnes of press force, the ventilation holes and the hub are stamped out, and the burring of excess material around the circumference cut off.

Step 5: The flow-forming

The outer edge of the wheel is heated. The complete rim area, from the outer to the inner flange, is rolled out – which is exactly what goes to make a Fuchsfelge®.

Step 6: The finishing

The finishing takes place in the last step: turning, drilling and deburring. The complex process is finalized by painting.