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Best-In-Class Exhaust Housing


BRP-US Inc., Spruce Pine, North Carolina


Material: 356 aluminum. Process: Lost foam. Weight: 31.1 lbs. Dimensions: 21.4 x 19 x 7.2 in. Application: Integrated exhaust,


cooling, steering and mount housing for a marine engine. Converted From: Fabrication.


• T e casting replaced a 28-component assembly while maintaining the same overall weight of the original fabrication design and provided a $75.04 per unit cost savings.


• T e single-piece cast design eliminated the risk of failures, such as gasket relaxation and torque retention defects. T e success of the housing prompted similar consolidations on other marine engine applications.


Front Steering Knuckle Compass Automotive Group Fruitport, Michigan


Material: A356 T6 aluminum. Process: VRC/PRC. Weight: 9.15 lbs. Dimensions: 24 x 9 in. Application: Tesla Model S sedan.


• T e world’s fi rst series production application for a fully hollow cast aluminum steering knuckle, the design utilized a sand core that extends from the upper ball joint attachment to the lower ball joint, with an extension into the steering arm.


• T e part represents a 25% weight savings over a solid aluminum arm and a 65% weight savings compared to a ductile iron knuckle.


PEOPLE’S CHOICE The front steering knuckle


produced by Compass Automotive Group, Fruitport, Mich., tallied the most votes in this year’s fi rst ever People’s Choice Casting Competition in which readers chose their favorite casting. The casting earned 2,359 votes.


May/Jun 2012 | METAL CASTING DESIGN & PURCHASING | 29


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