Abstract: A method of fusion welding two ferrous alloy component parts, at least one of which is considered unweldable, involves placing a low carbon steel band into a groove defined in part by each of the ferrous alloy component parts and then conveying a concentrated energy source along a welding line that overlaps the low carbon steel band to melt the steel band along with adjacent portions of the ferrous alloy component parts to form a blended alloy weld pool. The blended alloy weld pool solidifies behind the forward movement of the concentrated energy source into a weld joint that fusion welds the ferrous alloy component parts together. The ferrous alloy component parts may include a differential casing and a ring gear. In that regard, a differential casing and ring gear assembly that includes a weld joint is also disclosed.

Abstract: A method of fusion welding two ferrous alloy component parts, at least one of which is considered unweldable, involves placing a low carbon steel band into a groove defined in part by each of the ferrous alloy component parts and then conveying a concentrated energy source along a welding line that overlaps the low carbon steel band to melt the steel band along with adjacent portions of the ferrous alloy component parts to form a blended alloy weld pool. The blended alloy weld pool solidifies behind the forward movement of the concentrated energy source into a weld joint that fusion welds the ferrous alloy component parts together. The ferrous alloy component parts may include a differential casing and a ring gear. In that regard, a differential casing and ring gear assembly that includes a weld joint is also disclosed.

Abstract: A system of components includes a first component including a first joint portion, and a second component including a second joint portion abutting the first component. At least one of the first and second components is formed from cast iron. The first joint portion and the second joint portion, when aligned, form a V-Shaped groove having a groove opening, a groove bottom angle of between about 10° and about 20° and a weld nugget envelope defined therebetween. The groove opening is wider than an outer diameter of a filler wire employed to form a metallurgical bond between the first component and the second component.

Abstract: An induction hardening heat treatment method comprises the steps of induction heating a metal part or component, particularly a part fabricated of a high strength material, and then exposing the part to a sequence or series of partial, intermittent or interrupted quenches. Such intermittent or interrupted quenching achieves the necessary change in surface temperature with time to achieve a martensitic transformation of the surface adjacent metal or material while minimizing surface to core temperature differentials during the process which could result in cracking of the part, especially if it is fabricated of high strength materials.

Abstract: The present invention provides a fluid filter comprising a magnetic substrate configured to allow passage of fluid therethrough, with the substrate manufactured from sintered powdered metal. Preferably, the filter has a porosity of at least 10%, and a magnetic flux density of at least 5 gauss. The substrate may include iron, aluminum, barium, cerium, cobalt, chromium, molybdenum, nickel, oxygen, praseodymium, platinum, samarium, and/or strontium. The present invention also provides a method of manufacturing a fluid filter by sintering powdered metal to form a magnetic substrate configured to allow passage of fluid therethrough. The method may further include shaping the magnetic substrate for use within a desired application.

Abstract: A double carboaustempering combined with a martensite-producing quench provides plain-carbon and low alloy steel power transmission shafts with a carbon-rich exterior having a martensite and bainite microstructure and a substantially bainite interior. The shafts offer increased fatigue resistance.