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An Example in Aluminum Casting   The Corvette Brake Pedal

How Can an Aluminum Casting
Save Weight?

The Challenges -- The GM engineers had the mission of reducing the overall weight of the new Corvette.  Weight savings translate into improved performance and better fuel economy.

This required a comprehensive review of every component in the car, looking to cut, not just ounces, but pounds on every component.

The weight reduction had to be done with no cost penalty, or even better, a cost benefit.

The previous brake pedal design utilized a welded steel assembly with a total weight of 6 pounds. 

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Benefits of Using an Aluminum Casting --Aluminum is the obvious light-weight material replacement for steel in this application. Specific benefits in using an aluminum casting were --
  • Reduced weight from 6 pounds to 1.7 pounds
  • A high tech appearance for the brake pedal with the elimination of the rubber boot on the foot pad section.
  • Reduction of machining requirements, compared to the original steel assembly.
  • Elimination of the fixturing, welding, and finishing operations required for the original steel welded assembly.


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Address Comments to: jss@afsinc.org
 
Last Modified:October, 1999 by STG

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