Mechanical properties of castings and their dependence on alloying, process parameters and related porosity, joining processes, and in-service corrosion. Performance requirements of aluminum castings used in structural and powertrain components of vehicles: functions, load cases, and failure modes. Design requirements: stiffness, durability, permanent set, clamping analysis, crash performance. Failure mode and effect analysis (FMEA) and trouble shooting for castings. Design for manufacturability, mold design, product design guidelines. Sizing calculations. Product optimization methods using finite element analysis tools. Design and optimization case studies. Post-secondary processes affecting product performance: final machining processes, trimming, heat treatment, component straightening, cleaning, and joining processes. Mould materials, mould heat treatment and coating, and mould design affecting product quality and performance.