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DIE-CAST ZA-27 DOUBLES

STRENGTH FOR SUPERWINCHThanks to high-strength ZA-27 casting alloy,Superwinch Inc., Putnam, Connecticut,eliminated a costly design project, solved amarketing problem, doubled their product

line, and it didnt cost them a cent for a newdie-cast tooling. ZA-27 is one of EasternAlloys new zinc-al uminum (ZA) cas ting

was introduced ten years ago and is re-

nowned for its simplicity, durability and effi-ciency. Superwinch also manufactures aheavy duty 8,000 lb. rated winch of a dif-ferent gear design.

A product gap had originally existed be-

tween their two winches (1,500 & 8,000 lb.ratings). We didnt manufacture anything inbetween and our marketing people wantedmedium load winches for the growing smalltruck market stated Bob Nelson, Engineer-ing Manager. I was faced with an 18-monthdesign project to develop the desired prod-ucts. Fortunately ZA-27 came along andshortened that effort by nearly a year.

Bob Nelson explains, Our 1,500 lb. units(X1 & M1) will remain as is with aluminumring gears, while our X2 & M2 models (2,500

Ibs. load) will use one aluminum casting withthe more critical rotating ring gear in ZA-27.Our 3,500 lb. rated X3 & M3 winches will useZA-27 die castings for both gear housings.(X models are for front mounting on vehicles;M models are for rear mounting) Bob also ad-vised, The superior performance of ZA-27 ispartially due to the natural lubricity andhigher hardness of ZA-27 castings whichreduces friction and therefore increasesgear load capabilities and wear resistance.Superwinch was most impressed with thetooling cost savings which allowed them tomake three products from one set of die

alloys which was developed for sand castingbut now is a valuable new cold chamberdie-casting alloy for high-strength, wearresistant applications.

What happened was quite simple. Supswinch tried ZA-27 ring gear die castings us-ing the same dies which manufacture thenew 1,500 lb. (aluminum) winch. Comparisonstrength tests showed ZA-27 gears weremore than two-and-one-half times strongerthan the 380 aluminum die castings. In fact,Superwinch could not break ZA-27 compo-nents even when tested to 5,000 lb. loadThe result was two new winches with load

capabilities of 2,500 Ibs. and 3,500 Ibs. usingZA-27 parts.

Superwinch is the producer of the worlds

most popular electric winches for recrea-tional applications. Their recreational prod-ucts are mounted on cars, trucks, jeeps andtrailers for self-winching in rough terrain, orfor winching boats, or for any general pur-pose pulling requirement. Superwinch incor-porates two die-cast housings which act asrotating and stationary ring gears. Steelgears transfer winch loads to both die-casthousings and drive the rotating housingwhich in turn drives the cable take-up shaftfor winching. The gear design has beenmainstay with Superwinch since the product

Efficient Superwinch design shows sun gear, driven by electric motor, and plant gearswhich revolve against 5-inch diameter die-cast ring gear housings (stationary and rotating).ZA-27 and aluminum parts are made in the same die-cast tools. ZA-27 components are usedonly in high-load winch modes where the superior strength and natural lubricity of ZA-27 isrequired.

casting dies. Other components for the new problems and helped create two new prod-models required redesigns and strengthen- ucts. Can ZA-27 or one of our other ZA cast-

ing to meet higher load ratings. ing alloys do the same for you? Why not giveThe Newton New Haven Company, North Eastern Alloys a call. Were the leadingHaven, Connecticut, die cast the aluminum technical experts on zinc alloys and canand ZA-27 gear housings for Superwinch. answer your design or production questions.Trevor N. Davis, VP of sales, stated, We Ask for our full complement of ZA technicalforesee ourselves casting more ZA-27 parts Support literature on sand casting, die cast-when superior strength and good wear prop- ing, graphite mold casting (another new de-erties are needed. velopment) and on ZA for bearing applica-

For Superwinch, ZA-27 solved a lot of tions. Just call or write Derek Cocks.

east ern a l loys, inc .P. O. Box Q, Maybrook, N.Y. 12543 (845) 427-2151

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