<p>Based on previous research, to further enhance the mechanical properties of large aluminum alloy wheel hubs, minimize local defects in the wheel core and spokes, and improve production stability, the wheel hub casting process was optimized by introducing the dual squeeze casting process, which involves a local secondary forging process based on a single squeeze molding. The finite element method was applied to simulate the thermal–fluid–solid coupling during the dual squeeze casting of aluminum alloy wheel hubs. The focus was on analyzing the flow and crystallization solidification behavior of the alloy melt under the pressure of the injection punch, as well as the influence of key process parameters during a single squeeze forming process, such as the mold temperature, alloy melt pouring temperature, injection speed, injection-specific pressure, and secondary local forging start time, forging specific pressure, on the quality of castings. By simulating and predicting the locations of casting defects, the optimal process parameters for eliminating these defects were determined. In addition, the correctness of the defect prediction and the optimization of the dual squeeze casting process parameters were verified through microstructure and mechanical property tests. The results provide theoretical support for obtaining dual squeeze casting wheels with stable performances and low weights.</p>