Abstract: A method of welding two workpieces together is described. A conductor in electrical communication with a pulse circuit is provided. A portion of the second workpiece is located adjacent the conductor. The two workpieces are also located together. A portion, or all, of one workpiece is welded to the other by applying a pulse current to one of the workpieces. A method of forming a workpiece is disclosed using a pulse current to move the workpiece into a desired shape.

Abstract: A slip yoke assembly including a slip yoke having a long bore extending between a first end and a second end and a counterbore at the second end of the long bore. The counterbore has a first wall which defines a first diameter which is greater than a major diameter of the long bore. An annular groove is positioned between the long bore and the first diameter. A sealing member is disposed within the annular groove. The slip yoke assembly also includes a plug disposed within the counterbore and over the sealing member. The plug is secured to the slip yoke by a lip formed over the plug.

Abstract: A shaft assembly includes a first shaft. The first shaft has a first annular crest and a second annular crest. The first annular crest and the second annular crest are separated by an inclined surface. The second annular crest includes an axially extending surface attached to an end of the inclined surface. A boot is secured to the shaft. The boot includes a channel and a diaphragm portion disposed adjacent an end of the channel. The channel includes an inlet portion, a partially helical portion, and an outlet portion formed in an inner surface of the boot. The diaphragm portion is provided over the inclined surface and includes a lip which contacts the second annular crest.

Abstract: A slip yoke assembly including a slip yoke having a long bore extending between a first end and a second end and a counterbore at the second end of the long bore. The counterbore has a first wall which defines a first diameter which is greater than a major diameter of the long bore. An annular groove is positioned between the long bore and the first diameter. A sealing member is disposed within the annular groove. The slip yoke assembly also includes a plug disposed within the counterbore and over the sealing member. The plug is secured to the slip yoke by a lip formed over the plug.

Abstract: The present invention is directed to an insert for a cylinder head gasket for an internal combustion engine. The cylinder head gasket may be made from metal, a composite material, or a combination of the two, and is disposed between a cylinder head and a cylinder block. The insert has an outer plate having upper and lower surfaces, an outer perimeter and a closed inner perimeter. A removable molded insert is located within the closed inner perimeter of the outer plate. The removable molded insert has a bead portion and an inner land portion. A metallic carrier is substantially enclosed within the bead portion and planar portion of the removable molded insert. The removable molded insert may be attached to the outer plate by mechanical or chemical means. The insert may be attached to a cylinder head gasket by mechanical means.

Abstract: A slip yoke assembly is provided. The slip yoke assembly includes a slip yoke having a long bore extending between a first end and a second end and a counterbore at the second end of the long bore. The counterbore has a first diameter and a second diameter. The first diameter is greater than a major diameter of the long bore and the second diameter is greater than the first diameter. The slip yoke assembly also includes a plug having an elastomeric member secured to a surface thereof. The elastomeric member is disposed within the first diameter and the plug is disposed within the second diameter. The plug is secured to the slip yoke by a lip formed over the plug.

Abstract: An inner race and boot sleeve combination is provided. The inner race has an inner surface with a groove formed therein. The boot sleeve has a groove in an outer surface. A ring is located in both grooves to axially secure the inner race and boot sleeve together. Devices to prevent relatively rotation between the inner race and the boot sleeve are also provided.

Abstract: An inner race and boot sleeve combination is provided. The inner race has an inner surface with a groove formed therein. The boot sleeve has a groove in an outer surface. A ring is located in both grooves to axially secure the inner race and boot sleeve together. Devices to prevent relatively rotation between the inner race and the boot sleeve are also provided.

Abstract: A method for protecting joined workpieces from salt or other environmental hazards is described. The method may include joining an end fitting into a driveshaft tube which results in a gap between the two. The gap may be cleaned and dried before a moisture protecting urethane coating is applied. A urethane coating may be sprayed on as the joined end fitting and tube are rotated together. The coating penetrates into the gap and extends laterally beyond the gap and is subsequently cured with an ultraviolet light source.

Abstract: A method of forming a tie rod tube assembly by magnetic pulse welding is provided. The method can be used to form tie rod assemblies with a tie rod tube centerpiece that is parabolic in shape. In addition, the method can be used to form a tie rod assembly where the end fittings and centerpiece are made from different materials. Also described is a tie rod assembly manufactured using the method or methods of the invention.

Abstract: Described herein is an improved rack for efficient and safe storage and transport of cylindrical or near cylindrical product. The rack may be rectangular or square in shape and consist of a base with uprights, which may form the base rails on the sides of the rack, and side end rails. The base includes openings at predetermined intervals on its short sides and on its long sides to accept tines from a fork lift. The base further includes stringers and ribs. The stringers support cradles having two L-shaped sections which extend the length of the cradle. The base of the cradle includes teeth that engage with one or more ribs to allow the cradle to selectively lock into a predetermined position in the rack. The cradle base portion includes a cradle upper portion which may define product support sections. The product support sections are designed to support a cylindrical or near cylindrical product such as drive shaft tubes or tie rods for vehicles.

Abstract: In a first embodiment, at a time of magnetic pulse welding, a stepped tube profile machining process axially bores a walled tube from an end inward to a transition depth to form a section with a reduced wall thickness and then axially bores the walled tube from the transition depth to a fall off depth, thereby forming a section with a maximized welding wall section. In a second embodiment, also at a time of magnetic pulse welding, a surface angle tube profile machining process axially bores at a surface angle a walled tube from an end to a bore length to form an angular welding wall thickness inward to a maximized wall section. For both embodiments, the bored surfaces are virgin with no pits, oil, residue, or oxidation thereon, thus making the machined walled tubes available for immediate magnetic pulse welding.

Abstract: A plastic pan and a plastic drain plug assembly is disclosed. The pan has upstanding walls, a bottom wall, an exterior surface and an interior surface. One of the walls has an opening extending through it. On the exterior, the opening has a circular raised collar with cutouts opposite each other and stop tabs located between the cutouts. On the interior, the opening has a circular raised non-threaded tubular wall. A portion of the non-threaded tubular wall has nibs projecting into the opening. The plug has a head portion, a body portion, an end portion. The head portion has an upstanding crown with downwardly extending tabs located opposite each other. The body portion has a circular groove, and a spiral groove. The end portion of the plug is tapered.

Abstract: A double offset constant velocity joint is provided. The constant velocity joint includes an outer element, an inner element, an annular element, and a plurality of torque transferring elements. The annular element has a first spherical outer surface, a second spherical outer surface, a spherical inner surface, and a plurality of perforations formed therethrough. The first spherical outer surface and the spherical inner surface have a center common with a spherical outer surface of the inner element. The second spherical outer surface has a center different from a joint pivot point and the first spherical outer surface. The second spherical outer surface has a diameter complementary to a diameter of the inner surface of the outer element. The annular element is disposed between the inner element and the outer element.

Abstract: A constant velocity joint assembly, and a method of securing a shaft to the assembly, the joint assembly including an outer race with a first portion having a plurality of grooves and a second portion that extends from the first portion and is substantially parallel to the shaft. The method of securing the shaft to the assembly includes the step of magnetically pulse welding the shaft to the outer race.

Abstract: The present invention relates to a multi-layer steel insert for a cylinder head gasket for an internal combustion engine comprising. The cylinder head gasket may be made from metal or a composite material, and is disposed between a cylinder head and a cylinder block. The MLS insert may be located around at least one fluid passage aperture. The MLS insert has a first outside layer and a second outside layer each comprising an upper surface and a lower surface, an outer perimeter, an inner closed perimeter defining a fluid aperture, and a bead. The beads may be half beads or whole beads. An intermediate layer is arranged between the outside layers and includes an upper surface and a lower surface, an outer perimeter and an inner closed perimeter defining a fluid aperture. The MLS insert may be attached to the cylinder head gasket by mechanical or chemical means.

Abstract: A shaft assembly is provided. The shaft assembly includes a first shaft. The first shaft has a first annular crest and a second annular crest. The first annular crest and the second annular crest are separated by an inclined surface. The second annular crest includes an axially extending surface attached to an end of the inclined surface. A boot is secured to the shaft. The boot includes a channel and a diaphragm portion disposed adjacent an end of the channel. The channel includes an inlet portion, a partially helical portion, and an outlet portion formed in an inner surface of the boot. The diaphragm portion is provided over the inclined surface and includes a lip which contacts the second annular crest.

Abstract: A method of forming a sliding spline-type joint using magnetic pulse forming technology includes providing a female driveshaft member and a splined insert having inwardly formed splines. A male driveshaft member is provided having outwardly formed splines engageable with the insert. A mandrel is provided having outer ribs similar to the outer spline profile of the male driveshaft member. An inductor is provided which is energized to create a pulse magnetic field. The insert is placed over the mandrel. The female driveshaft member is disposed over the insert, and both are placed inside the inductor. The inductor is energized to deform a portion of the female driveshaft member over the insert to form an array of crimps for permanently connecting the female driveshaft member with the insert. The male driveshaft member is engaged into the insert to provide a sliding spline-type of slip joint.

Abstract: An axially adjustable driveshaft assembly in a drive train system is described. Two hollow driveshaft sections, where one has a valve through an aperture in it and each has an end fitting, engage each other to form an axially adjustable driveshaft assembly that has a sealed internal chamber within. When a pressurized air or vacuum source is connected to the valve, air fills the chamber or air is removed from the chamber, which correspondingly increases or decreases a drive train system length. This results in facilitating the installation of the driveshaft assembly between a transmission and an axle assembly in a drive train system.

Abstract: An exhaust manifold gasket having at least two layers and a series of tabs and recesses. The gasket has a first outer layer and a second outer layer each with an outer surface, an inner surface, two bolt hole flanges, and a central aperture. The surfaces are bounded by an outer perimeter portion, with locator tabs and recesses. A first inner layer having an outer surface, an inner surface, two bolt hole flanges, and a central aperture. The surfaces are bounded by an outer perimeter portion with two sets of foldable tabs. The first inner layer also has a bead circumferentially around the central aperture. A second inner layer may be provided having an outer surface, an inner surface, two bolt hole flanges, and a central aperture. The surfaces are bounded by an outer perimeter portion with foldable tabs and recesses, and a bead circumferentially around the central aperture.