Abstract: A method for forming a component utilizing ultra-high strength steel and components formed by the method. The method includes the step of providing a flat blank of ultra-high strength 22MnB5 steel. The next step of the method is cold forming the flat blank into an unfinished shape of a component while the blank is in an unhardened state. Then, heating the unfinished shape of the component and generating a spline form thereon. The method proceeds by forming a finished shape of the component using a quenching die resulting in a fine-grained martensitic component material structure and enabling net shape processing to establish final geometric dimensions of the component.

Abstract: A component and method for forming the component utilizing ultra-high strength steel is provided. The method includes the steps of providing a blank of ultra-high strength steel and forming the blank into an unfinished component. Next, heating the unfinished component and moving an inner tooling member and an outer tooling member relative to one another to sandwich the heated component therebetween. Further, moving a punch member from a withdrawn, unactuated position to an extended, actuated position to contact the component while sandwiched between the inner and outer tooling members to form a feature including at least one of a thickened region having an increased thickness relative to an adjacent region, a recessed annular groove, a recessed pocket, a through hole, a flange, a through hole having a tab extending outwardly therefrom, or spline teeth. Then, quenching the feature.

Abstract: Components and methods for forming components utilizing ultra-high strength steel are provided. A first method includes the steps of providing a blank of ultra-high strength steel, cold forming the blank into an unfinished component, and applying a coating to the outer surface of the unfinished component that is adapted to inhibit the formation of a ferrite soft layer on the component during heating thereof. A second method includes the steps of providing a blank of heavy gauge thickness ultra-high strength steel, cold forming the blank into a finished component, heating the finished component and quenching the component without the use of tooling.

Abstract: A method for forming a component utilizing ultra-high strength steel and components formed by the method. The method includes the step of providing a flat blank of ultra-high strength 22MnB5 steel. The next step of the method is cold forming the flat blank into an unfinished shape of a component while the blank is in an unhardened state. Then, heating the unfinished shape of the component and generating a spline form thereon. The method proceeds by forming a finished shape of the component using a quenching die resulting in a fine-grained martensitic component material structure and enabling net shape processing to establish final geometric dimensions of the component.

Abstract: A component and method for forming the component utilizing ultra-high strength steel is provided. The method includes the steps of providing a blank of ultra-high strength steel and forming the blank into an unfinished component. Next, heating the unfinished component and moving an inner tooling member and an outer tooling member relative to one another to sandwich the heated component therebetween. Further, moving a punch member from a withdrawn, unactuated position to an extended, actuated position to contact the component while sandwiched between the inner and outer tooling members to form a feature including at least one of a thickened region having an increased thickness relative to an adjacent region, a recessed annular groove, a recessed pocket, a through hole, a flange, a through hole having a tab extending outwardly therefrom, or spline teeth. Then, quenching the feature.

Abstract: A method for forming a component utilizing ultra-high strength steel and components formed by the method. The method includes the step of providing a flat blank of ultra-high strength 22MnB5 steel. The next step of the method is, cold forming the flat blank into an unfinished shape of a component while the blank is in an unhardened state. The method continues by providing an inert atmosphere. Then, heating the unfinished shape of the component in the inert atmosphere. The method proceeds by forming a finished shape of the component using a quenching die resulting in a fine-grained martensitic component material structure and enabling net shape processing to establish fmal geometric dimensions of the components.