Nowadays the use of aluminum alloys for highly demanding structural components is increasing due to lightweighting needs. In this context, automotive suspension parts are usually made by forging that offers higher mechanical properties respect to castings.

On the other hand, castings are more affordable than forgings and are more suitable for the manufacturing of complex shapes. Thus, significant efforts have been made over the last few years both to improve quality and mechanical properties of castings and to combining the benefits of casting and forging with hybrid processes.

These new technologies are based on the application of a determinate pressure on a near-net-shape casting, in order to maximize the benefit of both casting (complex shape and low cost) and hot-deformation (higher mechanical properties). Metallurgically, the process is expected to yield products that have a more uniform microstructure, free of porosity and with superior tensile and fatigue properties. The hot deformation is expected to improve the mechanical, fatigue properties, surface finish and dimensional tolerance of the shaped casting. The present work deals with the potential application of this new process to structural components in the automotive field and the final effect on microstructure and mechanical properties.