Abstract: An integrally cast aluminum subframe for a vehicle suspension system has increased stiffness for an overall vehicle frame while minimizing the thickness of the main aluminum casting by using tension/compression struts to resist flexing. Various strut attachments are shown that simplify manufacturing and lower the cost. The invention results in further improvement of weight reduction while simultaneously achieving a desired amount of stiffness.

Abstract: An integrally cast aluminum subframe for a vehicle suspension system has control arm connections that avoid high stress in the connections. Mounting studs may be an integral part of the subframe casting or may be subsequently joined to the subframe. Bushings of the articulations of the control arms are joined to the mounting studs from one side only, so that the flexing of the connection that was present in the prior art clevis connection is avoided. Consequently, the articulation is retained between a head of the mounting bolt and the mounting stud.

Abstract: A spindle to aluminum wheel carrier mounting is provided having increased contact area for reducing stress in the aluminum. The wheel assembly comprises a spindle, a wheel carrier, and a fastener. The spindle is comprised of ferrous material and includes a shank portion, a boss portion, and a fastening portion. The boss portion has a monotonically changing diameter along its longitudinal axis. The wheel carrier is adapted to be supported by a suspension system of the vehicle and has a wheel-facing side. The wheel carrier is comprised of aluminum and has a spindle-receiving aperture therethrough. The aperture has a variable diameter along its length to form a boss-receiving socket. The boss-receiving socket has a monotonically changing diameter substantially matching the boss portion. A fastener is joined to the fastening portion and draws the boss portion against the boss-receiving socket. Consequently, stresses in the aluminum wheel carrier are distributed over the boss-receiving socket.

Abstract: A wheel assembly for a vehicle comprises a spindle and a wheel carrier. The spindle includes a shank portion and a shoulder portion. The shank portion includes a press-fit portion adjacent the shoulder portion and has a first predetermined diameter. The wheel carrier is adapted to be supported by a suspension system of the vehicle, is comprised of aluminum, and has a spindle-receiving bore therethrough. The bore has an initially-formed diameter smaller than the first predetermined diameter. The press-fit portion is press-fit into the bore. The difference between the initially-formed diameter and the first predetermined diameter is sufficiently large that the press-fit portion is surrounded by a deformation zone having a radial thickness of at least 10 microns. In one preferred embodiment, this deformation zone is comprised of plastically deformed aluminum having a radial thickness of at least 3 microns.