It’s the month of May, and here in Indianapolis that means it’s RACE MONTH! The Indy 500 dominates local news as race fans head to the Indianapolis Motor Speedway throughout the month to take in the sights and sounds unique to the greatest racetrack in the world. Being within a stones throw of “The Track” got us thinking about IndyCar construction and materials. After all, we’re in the metal business and these high-powered machines are engineered to get the most out of the materials used in their construction, including a variety of metals.

IndyCars are single-seater race cars capable of racing at speeds of over 200 mph. According the NTT INDYCAR Series website, the Dallara chassis or “frame” of an IndyCar, is made of carbon fiber, kevlar and “other composites.” But what are those “other composites,” and how do they contribute to the car’s performance?

The core of the car’s chassis is its survival cell, or monocoque housing which houses the driver and fuel tank. The survival cell is made from carbon fiber and aluminum, and undergoes stringent crash tests to ensure the driver’s safety.

And then of course, there’s the power behind the speed, the turbocharged engines of these specialized vehicles, along with the suspension, gearbox, and many other components. We took a closer look at the many metals utilized in IndyCar construction. Here’s what we learned:

Aluminum

Aluminum and its alloys are big in IndyCar construction, and are highly utilized due to their lightweight properties, high strength-to-weight ratio, and corrosion resistance. Aluminum components are found throughout the car, including the chassis, suspension components, and gearbox housings. The excellent machinability of aluminum also makes it a preferred choice for various intricate parts. The wheel rims for all IndyCar Series cars are made of aluminum alloy.

Titanium

Titanium is prized for its exceptional strength, corrosion resistance, and lightweight characteristics. In IndyCars, titanium is often used in critical components like suspension elements, gearbox components, and engine parts. Its high strength-to-weight ratio allows engineers to reduce weight without sacrificing structural integrity. Just this year, IndyCar introduced an update to a safety feature called the ”Aeroscreen,” which is designed to protect drivers from head and upper body injuries. It consists of a PPG-developed laminated polycarbonate ballistic windscreen reinforced with a titanium framework. The 2024 update of this safety feature includes a 3D-printed titanium frame that is 3kg lighter than the previous version. The technology is amazing! Check it out in this INDYCAR 101 Video.

Steel

While not as prevalent in lightweight racing cars, steel is still used in certain components that require high strength and durability. For example, steel is commonly used in the construction of roll cages and safety structures to ensure driver safety in the event of a crash.

Magnesium

Magnesium and its alloys are utilized in various lightweight components of IndyCars, such as wheels, gearbox housings, and certain engine parts. Like many of the metals used in IndyCar construction, magnesium offers excellent strength-to-weight ratio and heat dissipation properties, contributing to improved efficiency, faster acceleration and higher speeds.

Beryllium

In some specialized applications, beryllium and its alloys may be used in IndyCar construction. Beryllium is exceptionally lightweight and offers high stiffness, making it suitable for specific components where weight reduction and performance are critical.

These metals, along with advanced composite materials like carbon fiber, are carefully selected and engineered to meet the stringent performance, safety, and weight requirements of IndyCar racing. The combination of these materials helps to optimize the car’s speed, agility, and overall performance on the racetrack making the Indy 500, in our humble opinion, the most exciting sporting event in the world!

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