Understanding Wheel Construction

1 Why Choose Alloy Wheels Over Steel Wheels?

The answer to that lies in the drawbacks of steel wheels. Steels wheels are typically bulkier and larger than alloy wheels. This weight is directly reflected in the vehicle’s handling and driving dynamics as the weight contributes to greater unsprung mass which reduces the handling performance. Their construction is more utilitarian and less aesthetical which is why they are often covered with plastic trim to give a better finish to the wheels. Therefore, steel wheels are less presentable and also provide worse performance which is why an alternative had to exist.

Advantages Of Alloy Wheels

Alloy wheels provide a better choice for vehicle owners due to their many advantages over steel wheels:

1. Lighter And More Durable

Steel is inherently stronger than aluminum but that strength comes at the cost of weight. Alloy wheels are made from lighter metals like aluminum and magnesium and depending on their manufacturing process, their durability is equivalent to or more superior to steel counterparts. Specialized manufacturing processes are employed in the making of alloy wheels which creates a more densely packed wheel. This reduces the amount of material used but increases the strength. Alloy wheels do not bend or flex under heavy loads or cornering forces which makes them ideal for racing applications. This also means these wheels can be used with tubeless tires.

2. Improved Handling

The lighter construction of alloy wheels provides much better handling characteristics. Since alloy wheels are stronger and more rigid, they can perform better while cornering without flexing which translates to better driving performance. The steering effort is also reduced with the reduction in weight, which aids in faster steering responses and quick maneuvers.

3. Look Better

Alloy wheels can enhance the aesthetics of any vehicle and unlike steel wheels; alloys come in several designs and styles. Alloy wheels can also be manufactured to your desired shape, size, and finish. You can also customize the finish on alloy wheels by adding paint, chrome, powder coating, and wrapping. The look of alloy wheels is often their instant selling point as they are known to make even the ugliest car look better. Owing to their robust construction, alloy wheels can be shaped in the most intricate fashion, allowing a high degree of personalization and matching your exact styling needs. Even a standard set of alloys are a major visual upgrade to any old steel wheels.

4. Better Braking Performance

Steel wheels are mostly solid and have tiny cutouts for air circulation to vent the rotors and brakes. Alloy wheels, on the other hand, have open designs that allow better air circulation to the brakes, which help cool them faster – increasing their life and performance.

5. Do Not Rust

As we all know, steel is prone to rust. Even treated and coated steel wheels eventually start pitting and display rust spots. This greatly reduces their lifespan and diminishes strength, aesthetics, and performance. Alloy wheels do not have to deal with this issue as aluminum, magnesium, and nickel do not rust which ultimately increases their service life and maintains sturdiness. So even a rusty old car will showcase shiny alloys after years of use.

Clearly, the benefits of alloy wheels outweigh that of steel wheels and are the reasons why most manufacturers use alloy wheels on more of their models, and car owners are flocking to customized alloy wheels to improve the visual appeal of their vehicle along with performance advantages.

Disadvantages Of Alloy Wheels

Alloy wheels have a few downsides that you must be aware of. Most importantly, they are significantly more expensive than stock steel wheels due to material choice and manufacturing costs. Depending on the size of alloys you choose, you can even expect a stiffer ride and harsher ride comfort for the handling gains you get. Also, in case of damage to the wheel like a crack or dent, you cannot repair alloy wheels and instead need to replace them. These tradeoffs can be worthwhile depending on who you ask as the advantages are more in favor of alloy wheels than against them.

2 When To Choose Steel Wheels?

If your primary concern is wallet-friendliness and not aesthetics or handling performance then steel wheels are for you. The most notable use for steel wheels is through the winter months. During winter it is best to install winter tires that have much better traction (grip) on snowy and icy roads enabling safe driving and making them the ideal choice. Refer to this guide If you wish to learn more about winter tire and their advantages over all-season and other tire types.

Now installing winter tires can be quite the hassle. You only have two choices either temporarily replace your current tires with winter tires or get new permanent rims for the winter tires. If you go with the first option, you have to get winter tires of the exact same size as your regular tires. This creates an issue depending on your standard wheel size since winter tires need to be narrower and have larger sidewall height in order for them to perform ideally. So if your current wheels are too wide or very large in diameter then you cannot install winter tires effectively. This only leaves you with option two of getting permanent wheels, which may sound counter-intuitive at first but actually is more economical in the long run.

Removing and reinstalling tires before and after the winter months is going to prove laborious and also going to cost you considerably. Instead, if you get permanent steel wheels for winter tire use, you do not have to worry about replacing or reinstalling winter tires. All you have to do is install the steel wheels with winter tires and you’re set. Additionally, steel wheels cost much lower than alloy wheels, and since driving fast in those months won’t be a requirement, winter tires with steel wheels are the perfect pair. This also means you can get properly sized wheels for the best performance from your winter tires, essentially sweetening the deal.

3 Why Is Wheel Construction Important?

The construction of the wheels determines their cost and other parameters like weight and strength. Essentially weight and cost are inversely proportional meaning, the lighter the tire the more expensive the cost of production and hence the wheel itself. But choosing a lighter wheel will provide better performance so finding the sweet spot between performance and cost can help you determine your choice of wheel.

The construction process for steel and alloy wheels differs. In order for you to select the right wheels for your car, you need to be aware of the various construction processes involved that affect the price. So you can buy the tires with a better understanding of the actual cost and make a more informed decision regarding your wheel purchase.

4 Steel Wheel Construction

Steel wheels date back to the early automobiles, and the construction processes haven’t changed much over the years. Steel itself is an alloy of carbon and iron. The type of steel composition comes from the percentage of carbon mixed with iron.  Steel wheels are typically made from two different sections. The cylindrical outer edge (rim) and the faceplate (center) that carries the hub bolting point. Both sections are stamped out of large steel sheets and then welded together to form a single wheel. Since steel is already very strong, it usually does not require further strengthening processes. Due to this manufacturing process, steel wheels lack the artistic flair that alloy wheels flaunt. Most steel wheels only have small openings to allow air circulation for brake cooling. This is why decorative hubcaps or wheel covers are used to disguise steel wheels with a more aesthetic appearance.

5 Alloy Wheel Construction

Alloy wheels have many advantages over steel wheels, but the biggest drawback to alloys is their cost of production. The production of alloy wheels involves complicated manufacturing processes that involve the use of expensive machinery, design and engineering expertise and high-value workmanship. These factors demand a lot of money and hence drive the prices of aluminium alloy wheels through the roof. Up until a few decades ago, alloy wheels were reserved for the top-notch models from various vehicle manufacturers and primarily used on luxury and racing models. With advancements in technology and reduction in production costs, alloy wheels gained popularity and are now used on a much larger scale with almost every manufacturer having made every model available with either standard or upgradable alloy wheels.

Aluminium alloy wheels are made of a mixture of magnesium, silicon, nickel, iron and other compounds. The content of various materials varies based on the manufacturer and the processes involved. Essentially aluminium wheels can be manufactured in two fashions; One-Piece or Multi-Piece wheels.

One-Piece Wheels

In this process, a single piece of aluminum is manipulated to create the wheel. This method of production is mainly used for aluminum wheels and provides a high degree of aesthetic appeal as well as high strength capabilities, depending on the manufacturing method. There are two ways to manufacture a one-piece wheel: Casting and Forging.

1. Casting

Casting is the process of pouring molten metal into a mold. The casting process does not produce a very dense wheel and so to compensate for the lack of strength, more material is used which leads to a heavier wheel. Since the casting process itself does not yield a strong wheel, further hardening and strengthening processes are required to meet safety standards. There are several different types of casting methods available.

2. Gravity Casting

This is the simplest form of casting as molten metal is poured into the mould using just the force of gravity to push the metal throughout the mould. This creates the least dense wheel which is why it is heavier to maintain strength. This method of casting is more economical than other methods and is primarily used where weight reduction is not a priority or more aesthetic designs are required.

3. Pressure Casting

In this method, molten metal is forced (injected) into the mould with pressure which packs the metal more densely thereby increasing strength and reducing weight. The most commonly used pressure casting method is Low-Pressure Die Casting (LPDC). However other such casting methods exist like Counterpressure Casting and High-Pressure Die Casting (HPDC). LPDC wheels are more expensive than gravity cast wheels but have better mechanical properties like lighter weight and more strength. HPDC wheels provide even better characteristics but at a higher cost. Therefore LPDC wheels provide a good common ground between performance and cost and are the reason why they are most commonly used as OE wheels and widely sold in the aftermarket.

4. Forged

This method involves forcing a solid block or billet of aluminum into dies using a tremendous amount of pressure and heat to compress the solid piece into the desired shape and form. Forging is superior to any other manufacturing process because the final product is immensely light and dense with very high strength and stiffness. Since this method utilizes expensive equipment, tools, development, and engineering expertise, the price of forged wheels is very high. Such wheels are mainly used in racing and performance applications.

5. Flow Forming

Flow forming utilizes both casting and forging technologies. The process starts off with low-pressure casting. This cast is then spun, stretched, and formed under heat and pressure to form the wheel of the desired size. This combination process produces a wheel similar in construction to a forged wheel while retaining lower costs compared to a fully forged wheel. The end product is a densely packed, lightweight wheel with enhanced strength and rigidity than a cast wheel.

Multi-Piece Wheels

Multi-piece wheels are made from more than one section that are joined together using bolts. This production method dates back to the ‘70s when they were first used in racing applications. There are two and three-piece wheels where one section is the rim or barrel and the other is the faceplate or centre. Three-piece wheels have two rim sections. The manufacturing of various sections can also differ. The centres are usually cast or stamped, whereas the rim is spun from a disc or sheet of aluminum. All sections are bolted together, which also allows customization. Three-piece wheels can be made wider with different rim sections, or the look can be altered by changing the faceplate. The wheel offset can also be customized. In case of damage to one part, replacements can be made more easily and economically without repairing or replacing the entire wheel. They are generally much stronger than cast wheels due to the greater number of structural components. The main disadvantage to multi-piece wheels lies in their high initial cost. These types of wheels can easily cost twice or thrice a standard cast wheel.