Abstract: A method for implementing pre-heat treatment before spray forming begins to achieve stress control in the manufacture of a spray formed metallic article involves preheating either or both of a spray forming cell environment and a mold substrate, initiating application of the metallic spray forming material onto the mold substrate, and causing substantially homogenous initial metallic phase transformations from the austenite phase via a predetermined relationship between the initial application temperature of the spray-forming material and the initial temperature of either or both of the preheated cell environment and the preheated mold substrate.

Abstract: A differential mechanism includes a housing portion having a generally annular wall with a generally annular inner surface. The annular wall defines an open end of the housing portion. The lid is affixed to the open end forming an enclosure with the housing portion. The opposing side bevel gears are in driving engagement with at least one bevel pinion assembly. The bevel pinion assembly includes at least one bevel pinion shaft with opposing axial ends, each supporting a side bevel gear. The bevel pinion assembly and the side bevel gears are disposed within said enclosure. The annular inner surface defines at least two receptors having ingress's, each receptorengaging one axial end of the pinion shaft independently of the lid.

Abstract: A torque converter housing includes an end cover that is secured to an impeller outer wall in a unique manner. The outward portions of the end cover extend in a radial direction but not in an axial direction. The end cover preferably does not extend axially beyond a plane of a clutch supported within the assembly. The impeller outer wall extends axially beyond the plane where it is secured to the end cover. The inventive arrangement changes the location of the connection between the impeller outer wall and the end cover, which enables the use of various other optional and advantageous features of the inventive arrangement. In one example, the impeller outer wall is welded to the end cover. In another example, a threaded connection secures the impeller outer wall to the end cover.

Abstract: A method of making a spray formed rapid tool includes the steps of making a model of a desired tool and constructing a ceramic pattern as the inverse of the model. The method also includes the steps of heating the ceramic pattern and thermally spraying a metal material against the ceramic pattern to form a desired tool.

Abstract: A method for implementing pre-heat treatment before spray forming begins to achieve stress control in the manufacture of a spray formed metallic article involves preheating either or both of a spray forming cell environment and a mold substrate, initiating application of the metallic spray forming material onto the mold substrate, and causing substantially homogenous initial metallic phase transformations from the austenite phase via a predetermined relationship between the initial application temperature of the spray-forming material and the initial temperature of either or both of the preheated cell environment and the preheated mold substrate.

Abstract: A method of making a spray formed rapid tool includes the steps of making a model of a desired tool and constructing a ceramic pattern as the inverse of the model. The method also includes the steps of heating the ceramic pattern and thermally spraying a metal material against the ceramic pattern to form a desired tool.

Abstract: A limited slip differential assembly 100. The differential assembly 100 includes first and second housing portions 104, 106 which are formed by use of a flow-forming or spin-forming process and which respectively include an integrally formed splined inner surface 154, 156. The integrally formed splined inner surfaces 154, 156 are used to mate with clutch plates 146 which cooperate with clutch plates 144 to form clutch packs 150, 152. The novel splined engagement of clutch plates 146 and surfaces 154 and 156 provide improved durability, stiffness and torque capacity relative to prior designs.

Abstract: A process for forming a precision formed cup-shaped member includes stamping a blank into a cup-shaped member. The cup-shaped member is positioned onto a magnetic heating machine. A magnetic core is positioned adjacent a radius of the cup-shaped part on both a top side and a bottom side of the cup-shaped part. The part is heated with the magnetic heating machine so as to anneal the cup-shape part at the radius.

Abstract: A housing for differential mechanism is formed in two pieces using a cold flow-forming process. Each of the housing portions is formed with an internal hemispherical surface, and semi-circular recesses, which when aligned form circular recesses within which a pinion shaft is seated. A subassembly that includes the pinion shaft, pinion gears, side bevel gears, and a thin plastic liner surrounding the subassembly is located within a lower housing portion so that the pinion shaft is seated in the recesses. The upper housing portion is inserted within the upper portion and welded. A ring gear is joined to a housing portion.

Abstract: A housing for differential mechanism is formed in two pieces using a cold flow-forming process. Each of the housing portions is formed with an internal hemispherical surface, and semi-circular recesses, which when aligned form circular recesses within which a pinion shaft is seated. A subassembly that includes the pinion shaft, pinion gears, side bevel gears, and a thin plastic liner surrounding the subassembly is located within a lower housing portion so that the pinion shaft is seated in the recesses. The upper housing portion is inserted within the upper portion and welded. A ring gear is joined to a housing portion.

Abstract: A housing for differential mechanism is formed in two pieces using a cold flow-forming process. Each of the housing portions is formed with an internal hemispherical surface, and semi-circular recesses, which when aligned form circular recesses within which a pinion shaft is seated. A subassembly that includes the pinion shaft, pinion gears, side bevel gears, and a thin plastic liner surrounding the subassembly is located within a lower housing portion so that the pinion shaft is seated in the recesses. The upper housing portion is inserted within the upper portion and welded. A ring gear is joined to a housing portion.

Abstract: A sleeve having a wear resistant surface is fitted over and secured to the outer surface of a hub for a bladed torque converter wheel. The sleeve may be secured by mechanical interference, bonding, or welding. The sleeve is adapted for use in transmissions for front-wheel drive and rear-wheel drive vehicles and is suitably formed for engagement with various drive connections.

Abstract: Method of making a rapid tool, comprising: making a plastic pattern of the tool by free form fabrication techniques following a computer aided design, the design having a base and no undercuts taken in a direction perpendicular to base; constructing a ceramic mold as the inverse of the pattern; separating the pattern from the mold by a separating movement in a direction perpendicular to the base to leave a surface defining a casting cavity within the mold; and thermally spraying tool steel particles against the casting cavity surface is a thickness exceeding 1 inch while rapidly cooling the sprayed particles to effect a net shape tool without the need for further working or heat treatment.

Abstract: A lockup clutch assembly and fabrication method for a hydrokinetic torque converter comprising a high capacity piston and clutch assembly located within the cover of the hydrokinetic torque converter, the piston and clutch assembly comprising a first friction disc and a second friction disc connected drivably to the torque input member of a multiple ratio geared transmission and a third friction disc situated between the first and second friction discs and connected to the cover of the torque converter, the second friction disc being adapted to engage a friction surface on the cover when a pressure differential across the piston and clutch assembly is created in the torque converter, the driving connection between the third disc and the cover being achieved by interlocking spline teeth or embossments which permit torque transfer from the cover through the piston and clutch assembly while accommodating relative axial displacement between them whereby a direct drive torque transfer path is established with mini