needed to incorporate gate sawing into its tooling plans due to its gating design. Datum schemes, or machining locators, were designed and put into place, as well. The company cast the hous- ing using its own, proprietary alloy (XK360 or 362.0), a high-strength ductile aluminum alloy close to A360. This particular alloy was cho- sen for its increased corrosion resis- tance and mechanical properties. After six months, Mercury


Marine was producing HPDC transmission housings for Fisker’s Karma. The finished die casting weighs in at just under 55 lbs., mea- suring 15 x 13 x 14.25 in. “We expedited the tooling design


and procurement process to less than six months as timing was of the utmost importance. Tis was achieved by using our internal tooling division, Capitol Engineering out of Brook- field, Wis.,” Olson said.


The Karma’s main transmission housing weighs in at 55 lbs. and shows off high pressure die cast design and casting capabilities.


February 2013 MODERN CASTING | 27


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