Abstract: A brake assembly that includes a brake pad assembly, a pad spring, and a sensor unit. The brake pad assembly includes friction material disposed on a backplate. The pad spring is mounted to the backplate. The sensor unit straddles the backplate and extends from the backplate to the pad spring.

Abstract: A method of controlling an axle assembly. At least one wheel hub may be operatively connected to a differential assembly having a ring gear when the ring gear does not receive torque from a torque source. Torque from the wheel hub may rotate the ring gear and the ring gear may provide splash lubrication.

Abstract: A system for making a welded assembly. The system may include a welding system that projects a laser beam that welds a first part to a second part. The system may further include a gas delivery device defining an interior cavity. The gas delivery device may include an inlet that provides pressurized gas to the interior cavity, and a discharge slot that receives the pressurized gas from the interior cavity and outputs the pressurized gas with substantially laminar flow toward the laser beam.

Abstract: A method of controlling a drive axle system. The drive axle system may include first and second drive axle assemblies. A drive axle assembly may be disconnected by operating a wheel end disconnect to discontinue transmission of torque between a wheel assembly and a differential and by discontinuing the transmission of torque to the differential.

Abstract: A system for making a welded assembly. The system may include a welding system that is configured to weld a first part to a second part with a laser beam. The system may further include an integrated feeder nozzle that includes an inlet manifold that receives a shield gas, and a nozzle body secured to the inlet manifold. The nozzle body may include a plurality of peripheral apertures that extend through the conical distal region and that are arranged around a central axis of the nozzle body. The system may further include a wire feeder disposed in the inlet manifold and the nozzle body. The wire feeder receives a welding wire and guides the welding wire to the central aperture.

Abstract: An axle assembly having an axle shaft subassembly. The axle shaft subassembly may include an axle shaft and an adapter ring. The adapter ring may receive the axle shaft and may be fixedly positioned with respect to the axle shaft. A hub may receive the adapter ring and may be fixedly positioned with respect to the adapter ring.

Abstract: A method of controlling a drive axle system. The drive axle system may include first and second drive axle assemblies. A drive axle assembly may be disconnected by operating a wheel end disconnect to discontinue transmission of torque between a wheel assembly and a differential and by discontinuing the transmission of torque to the differential.

Abstract: A drive axle system having a planetary interaxle differential unit. A shift collar may be movable along an axis between a first position and a second position. The shift collar may operatively connect a sun gear to a drive pinion when in the first position. The shift collar may operatively connect the sun gear to a planet carrier when in a second position.

Abstract: A drive axle system having a planetary interaxle differential unit. A shift collar may be movable along an axis between a first position and a second position. The shift collar may operatively connect a sun gear to a drive pinion when in the first position. The shift collar may operatively connect the sun gear to a planet carrier when in a second position.

Abstract: A method of controlling an axle assembly. At least one wheel hub may be operatively connected to a differential assembly having a ring gear when the ring gear does not receive torque from a torque source. Torque from the wheel hub may rotate the ring gear and the ring gear may provide splash lubrication.

Abstract: A differential assembly and a method of manufacture. The differential assembly may include a case that is rotatable about an axis and includes a first case portion and the second case portion. The first case portion may be joined to the second case portion with a first weld that may be disposed at an angle with respect to the axis.

Abstract: A system for making a welded assembly. The system may include a welding system that is configured to weld a first part to a second part with a laser beam. The system may further include an integrated feeder nozzle that includes an inlet manifold that receives a shield gas, and a nozzle body secured to the inlet manifold. The nozzle body may include a plurality of peripheral apertures that extend through the conical distal region and that are arranged around a central axis of the nozzle body. The system may further include a wire feeder disposed in the inlet manifold and the nozzle body. The wire feeder receives a welding wire and guides the welding wire to the central aperture.

Abstract: A system for making a welded assembly. The system may include a welding system that projects a laser beam that welds a first part to a second part. The system may further include a gas delivery device defining an interior cavity. The gas delivery device may include an inlet that provides pressurized gas to the interior cavity, and a discharge slot that receives the pressurized gas from the interior cavity and outputs the pressurized gas with substantially laminar flow toward the laser beam.

Abstract: A differential assembly and a method of manufacture. The differential assembly may include a case that is rotatable about an axis and includes a first case portion and the second case portion. The first case portion may be joined to the second case portion with a first weld that may be disposed at an angle with respect to the axis.

Abstract: An axle assembly having an axle shaft subassembly. The axle shaft subassembly may include an axle shaft and an adapter ring. The adapter ring may receive the axle shaft and may be fixedly positioned with respect to the axle shaft. A hub may receive the adapter ring and may be fixedly positioned with respect to the adapter ring.

Abstract: A system and method of making a forged part. A flange may be forged between first and second ends of the part by actuating an upset punch against a second end of the tube that is disposed opposite the first end. The flange may extend away from an axis along which an upset punch is actuated.

Abstract: A system and method of making a forged part. The method may include forming a workpiece in a first die unit that may be disposed in a first press, transferring the workpiece to a tooth forming die unit that may be disposed in a second press, and forming the workpiece into the forged part by forming a set of teeth on the workpiece with the tooth forming die unit.

Abstract: A method and a system of balancing a shaft for an axle assembly. The method may include depositing a powder composition onto the shaft to produce a balance weight proximate an imbalance location. The powder composition may be propelled by a heated supersonic gas and may plastically deform and mechanically interlock to the shaft.

Abstract: A system and method of making a welded assembly. The system may include a welding system and an ultrasonic inspection device. The welding system may be configured to weld a first part to a second part. The ultrasonic inspection device may transmit an ultrasonic beam to facilitate pre-weld inspection and/or post-weld inspection.

Abstract: A system and method of making a forged part. The method may include forming a workpiece in a first die unit that may be disposed in a first press, transferring the workpiece to a tooth forming die unit that may be disposed in a second press, and forming the workpiece into the forged part by forming a set of teeth on the workpiece with the tooth forming die unit.