Abstract: A differential assembly includes one or more NVH-modifying elements that alter and/or reduce at least one of a noise, vibration, and harshness emitted from the differential assembly. The NVH-modifying element(s) are placed in engagement with the side gears of the differential assembly to modify and/or reduce the NVH of the differential assembly.

Abstract: A forged composite inner race for a constant velocity joint is forged from a composite preform compact including a first powder metal material and a second powder metal material. The forged composite inner race includes a plurality of ball tracks formed on an outer section of the forged composite inner race with corresponding lands between adjacent ball tracks and an axially-extending splined opening formed in an inner section of the forged composite inner race. The outer section comprises the first powder metal material in a higher concentration than the second powder metal material and the inner section comprises the second powder metal material in a higher concentration than the first powder metal material.

Abstract: A differential assembly includes one or more NVH-modifying elements that alter and/or reduce at least one of a noise, vibration, and harshness emitted from the differential assembly. The NVH-modifying element(s) are placed in engagement with the side gears of the differential assembly to modify and/or reduce the NVH of the differential assembly.

Abstract: A forged composite inner race for a constant velocity joint is forged from a composite preform compact including a first powder metal material and a second powder metal material. The forged composite inner race includes a plurality of ball tracks formed on an outer section of the forged composite inner race with corresponding lands between adjacent ball tracks and an axially-extending splined opening formed in an inner section of the forged composite inner race. The outer section comprises the first powder metal material in a higher concentration than the second powder metal material and the inner section comprises the second powder metal material in a higher concentration than the first powder metal material.

Abstract: A forged composite bevel gear is forged from a composite preform compact including a first powder metal material and a second powder metal material. The forged composite bevel gear includes a gear core formed in an inner section of the forged composite bevel gear with the gear core defining a rotational axis and a plurality of teeth formed on an outer section of the forged composite bevel gear and extending from the gear core. The plurality of teeth extend in the same general direction as the rotational axis of the gear core, but are also inclined with respect to the rotational axis of the gear core. The outer section comprises the first powder metal material in a higher concentration than the second powder metal material.

Abstract: A forged composite powder metal part, such as a CVJ inner race or bevel gear, and method of making the same are disclosed. The forged composite powder metal part includes a outer section concentrated with a first powder metal material, a inner section concentrated with a second powder metal material and a variable boundary profile between the materials of the two sections. For example, in a forged CVJ inner race, the different materials can provide improved wear resistance in the ball tracks and improved spline performance. As another example, in a forged bevel gear, the different materials can be used to create a continuous variable boundary profile that defines the depth of a harder layer over the teeth.

Abstract: A component (10) is adapted for contact with a mating component (50) during attachment of the components to one another to form a related assembly in which a deformable pad (26) or pads improve stress distribution. The component includes a body having an interface surface in which the body is adapted to be contacted with the mating component at the interface surface of the body. One or more deformable pads are formed in the interface surface. Each deformable pad has a top surface that is offset outwardly from the interface surface relative to the body and a groove surrounding the deformable pad that is offset inwardly from the interface surface relative to the body.

Abstract: A component (10) is adapted for contact with a mating component (50) during attachment of the components to one another to form a related assembly in which a deformable pad (26) or pads improve stress distribution. The component includes a body having an interface surface in which the body is adapted to be contacted with the mating component at the interface surface of the body. One or more deformable pads are formed in the interface surface. Each deformable pad has a top surface that is offset outwardly from the interface surface relative to the body and a groove surrounding the deformable pad that is offset inwardly from the interface surface relative to the body.

Abstract: A process for manufacturing connecting rods is provided which comprises the steps of compacting, sintering, and powder forging a powder metal comprising a carbon source and a prealloyed powder consisting essentially of iron and copper. The connecting rods made from this process have sufficient hardness and strength to be used in an engine and do not require any additional quenching or tempering.

Abstract: A differential assembly, bevel gears for the assembly, and a method of making the bevel gears are disclosed. The bevel gears have a form which provides for high power density transfer.

Abstract: A forged composite gear and a method of making a forged composite powder metal gear. The forged composite gear includes a plurality of teeth extending from a core, a first section having a first powder metal material, a second section having a second powder metal material and a variable boundary profile. The variable boundary profile is formed between the first section and the second section, whereby said variable boundary profile exhibits greater tooth wear resistance on the teeth and greater impact resistance in the core.

Abstract: A forged composite powder metal part, such as a CVJ inner race or bevel gear, and method of making the same are disclosed. The forged composite powder metal part includes a outer section concentrated with a first powder metal material, a inner section concentrated with a second powder metal material and a variable boundary profile between the materials of the two sections. For example, in a forged CVJ inner race, the different materials can provide improved wear resistance in the ball tracks and improved spline performance. As another example, in a forged bevel gear, the different materials can be used to create a continuous variable boundary profile that defines the depth of a harder layer over the teeth.

Abstract: A differential assembly, bevel gears for the assembly, and a method of making the bevel gears are disclosed. The bevel gears have a form which provides for high power density transfer.

Abstract: A process for manufacturing connecting rods is provided which comprises the steps of compacting, sintering, and powder forging a powder metal comprising a carbon source and a prealloyed powder consisting essentially of iron and copper. The connecting rods made from this process have sufficient hardness and strength to be used in an engine and do not require any additional quenching or tempering.

Abstract: A forged composite gear and a method of making a forged composite powder metal gear. The forged composite gear includes a plurality of teeth extending from a core, a first section having a first powder metal material, a second section having a second powder metal material and a variable boundary profile. The variable boundary profile is formed between the first section and the second section, whereby said variable boundary profile exhibits greater tooth wear resistance on the teeth and greater impact resistance in the core.

Abstract: A gear and a method of making a forged powder metal gear having a plurality of teeth and a variable case depth profile forged in the plurality of teeth. Each tooth of the plurality of teeth has a first surface and a tooth root. A variable case depth profile is formed in each tooth of the plurality of teeth, whereby the variable case depth profile exhibits greater tooth wear resistance on the first surface and greater impact resistance in the tooth root.

Abstract: A method for obtaining a selectively non-carburized powdered metal part. The steps include compacting, sintering, removing, forging and cooling. A metal powder is compacted to form a preform having at least one first surface in which a forged part is required to have a case depth and at least one second surface in which a carburized portion is required to be removed prior to forging. The preform is then sintered and carburized. After carburizing the at least one second surface of the preform is removed and subsequently forged and cooled. The forged part has at least one second surface having improved post forging properties and at least one first surface having improved performance features. A part made from the present method is also provided.

Abstract: A presently-preferred process for manufacturing a connecting rod comprises placing a heated preform suitable for being formed into the connecting rod into a closed forge die, and forging the preform in a first forging operation while the preform is at a forging temperature to form an as-forged connecting rod having vertical flash extending therefrom. The presently-preferred process further comprises placing the as-forged connecting rod in a second forge die while the as-forged connecting rod is at a temperature substantially equal to the forging temperature, and forging the vertical flash in a second forging operation. The presently-preferred process also comprises removing the as-forged connecting rod from the second forge die, and machining the as-forged connecting rod to predetermined dimensions.

Abstract: A presently-preferred process for manufacturing a connecting rod comprises placing a heated preform suitable for being formed into the connecting rod into a closed forge die, and forging the preform in a first forging operation while the preform is at a forging temperature to form an as-forged connecting rod having vertical flash extending therefrom. The presently-preferred process further comprises placing the as-forged connecting rod in a second forge die while the as-forged connecting rod is at a temperature substantially equal to the forging temperature, and forging the vertical flash in a second forging operation. The presently-preferred process also comprises removing the as-forged connecting rod from the second forge die, and machining the as-forged connecting rod to predetermined dimensions.

Abstract: A unitary powder metal gear or sprocket (10) has a teeth region (16) which extends 2-5 mm below the tooth root diameter and a body region (14) radially inside of the teeth region (16). The teeth region (16) is pressed to a higher density than the body region (14) in a two chamber compaction die. The teeth region (16) is made of a sinter or induction hardening material, and the body region (14) is made of a liquid phase sintered material. Materials for the teeth (16) and body (14) regions are selected for compatibility by compacting them into a bimetallic strip (20, 22) with the teeth material (18) on one side and the body material (19) on the other side, sintering the strip (20,22) and observing the amount it bends.