Casting Study: Gear Housing

Engineers decreased time-to-market by utilizing existing gear housing tooling to develop a higher load winch. Superwinch’s 1,500-lb. unit incorporated two 380 Aluminium die cast housings which functioned as rotating and stationary ring gears. By substituting ZA-27 alloy for 380 Aluminium, the two new gear housings are cast in the original tooling but provide 2-1/2 times more strength. Without incurring additional tooling costs, Superwinch introduced a new 3,500-lb. winch. The superior performance of ZA-27 is in part due to the natural lubricity and high hardness of the alloy, which reduces friction and increases load capability and wear resistance.