Abstract: A method for manufacturing a forging includes forming a bi-material billet by enclosing a core material other than steel in a steel cylinder with a cylindrical wall and steel end caps. The cylindrical wall is heated. The method includes a first forging blow on the heated billet or on a disk-shaped rough forging forged from the heated billet with a first closed blocker die to produce a forging preform, and a second forging blow on the preform with a second closed blocker die to produce a netshape forging. An evacuation hole is formed in a steel shell of the netshape forging and the core material is removed from the netshape forging via the hole. At least 85 percent of the core material is in a liquid phase during the first and second forging blows, and removal of the core material.

Abstract: A method for manufacturing a gear includes forming a bi-material billet from a steel cylinder having a cylindrical wall, a first end closed with a first steel cap, and an open second end distal to the first end. The method includes disposing a core material other than steel into the steel cylinder, welding a second steel cap onto the steel cylinder to form the bi-material billet, and heating the cylindrical wall. The method includes a first forging blow on the heated billet or on a disk-shaped rough forging forged from the heated billet with a first closed blocker die to produce a partial toothed preform, and a second forging blow on the preform with a second closed blocker die to produce a netshape gear. The first closed blocker die has a die cavity including gear tooth forms, and the partial toothed preform includes a plurality of spaced gear teeth.

Abstract: A method for manufacturing a forging includes forming a bi-material billet by enclosing a core material other than steel in a steel cylinder with a cylindrical wall and steel end caps. The cylindrical wall is heated. The method includes a first forging blow on the heated billet or on a disk-shaped rough forging forged from the heated billet with a first closed blocker die to produce a forging preform, and a second forging blow on the preform with a second closed blocker die to produce a netshape forging. An evacuation hole is formed in a steel shell of the netshape forging and the core material is removed from the netshape forging via the hole. At least 85 percent of the core material is in a liquid phase during the first and second forging blows, and removal of the core material.

Abstract: A friction plate for a clutch assembly includes a core plate and a plurality of friction segments made of a friction material. A plurality of grooves are disposed between said plurality of friction segments. Each segment has tapered sides so that the grooves have a first width adjacent the outer diameter of the core plate and a smaller second width smaller adjacent the inner diameter of the core plate. This tapered groove structure directs oil from the outside the clutch assembly to the inside to improve cooling efficiency.

Abstract: A method for manufacturing a gear includes forming a bi-material billet from a steel cylinder having a cylindrical wall, a first end closed with a first steel cap, and an open second end distal to the first end. The method includes disposing a core material other than steel into the steel cylinder, welding a second steel cap onto the steel cylinder to form the bi-material billet, and heating the cylindrical wall. The method includes a first forging blow on the heated billet or on a disk-shaped rough forging forged from the heated billet with a first closed blocker die to produce a partial toothed preform, and a second forging blow on the preform with a second closed blocker die to produce a netshape gear. The first closed blocker die has a die cavity including gear tooth forms, and the partial toothed preform includes a plurality of spaced gear teeth.

Abstract: A friction material includes a resin and a fibrous base material impregnated with the resin. The fibrous base material has a single ply, and includes a plurality of aramid fibers present in a first amount, a plurality of polyacrylonitrile-based carbon fibers present in a second amount that is less than the first amount, a plurality of carbon particles present in a third amount that is less than or equal to the second amount, a plurality of mineral fibers present in a fourth amount that is less than or equal to the second amount, and diatomaceous earth present in a fifth amount that is greater than the first amount. A friction member for operatively contacting a lubricated surface includes a substrate and the friction material. The friction material defines a first surface bonded to the substrate and a second surface configured for operatively contacting the lubricated surface.

Abstract: A friction plate for a clutch assembly includes a core plate and a plurality of friction segments made of a friction material. A plurality of grooves are disposed between said plurality of friction segments. Each segment has tapered sides so that the grooves have a first width adjacent the outer diameter of the core plate and a smaller second width smaller adjacent the inner diameter of the core plate. This tapered groove structure directs oil from the outside the clutch assembly to the inside to improve cooling efficiency.

Abstract: A friction material includes a resin and a fibrous base material impregnated with the resin. The fibrous base material has a single ply, and includes a plurality of aramid fibers present in a first amount, a plurality of polyacrylonitrile-based carbon fibers present in a second amount that is less than the first amount, and diatomaceous earth present in a third amount that is greater than the first amount. The fibrous base material is substantially free from activated carbon. A friction member for operatively contacting a lubricated surface includes a substrate and a friction material. The friction material defines a first surface bonded to the substrate and a second surface configured for operatively contacting the lubricated surface.

Abstract: A friction material includes a resin and a fibrous base material impregnated with the resin. The fibrous base material has a single ply, and includes a plurality of aramid fibers present in a first amount, a plurality of polyacrylonitrile-based carbon fibers present in a second amount that is less than the first amount, and diatomaceous earth present in a third amount that is greater than the first amount. The fibrous base material is substantially free from activated carbon. A friction member for operatively contacting a lubricated surface includes a substrate and a friction material. The friction material defines a first surface bonded to the substrate and a second surface configured for operatively contacting the lubricated surface.

Abstract: A friction material includes a resin and a fibrous base material impregnated with the resin. The fibrous base material has a single ply, and includes a plurality of aramid fibers present in a first amount, a plurality of polyacrylonitrile-based carbon fibers present in a second amount that is less than the first amount, and diatomaceous earth present in a third amount that is greater than the first amount. The fibrous base material is substantially free from activated carbon. A friction member for operatively contacting a lubricated surface includes a substrate and a friction material. The friction material defines a first surface bonded to the substrate and a second surface configured for operatively contacting the lubricated surface.

Abstract: A permeameter including a fluid control chamber, a permeability specimen area, and a first outlet from the specimen area measuring fluid as a function of a normal permeability of at least one specimen in the specimen area and a second outlet from the specimen area receiving and measuring further fluid as a function of a radial permeability of the at least one specimen in the specimen area.

Abstract: A friction material includes a resin and a fibrous base material impregnated with the resin. The fibrous base material has a single ply, and includes a plurality of aramid fibers present in a first amount, a plurality of polyacrylonitrile-based carbon fibers present in a second amount that is less than the first amount, a plurality of carbon particles present in a third amount that is less than or equal to the second amount, a plurality of mineral fibers present in a fourth amount that is less than or equal to the second amount, and diatomaceous earth present in a fifth amount that is greater than the first amount. A friction member for operatively contacting a lubricated surface includes a substrate and the friction material. The friction material defines a first surface bonded to the substrate and a second surface configured for operatively contacting the lubricated surface.

Abstract: A permeameter including a fluid control chamber, a permeability specimen area, and a first outlet from the specimen area measuring fluid as a function of a normal permeability of at least one specimen in the specimen area and a second outlet from the specimen area receiving and measuring further fluid as a function of a radial permeability of the at least one specimen in the specimen area.

Abstract: A friction material which includes a porous base material, at least one type of resin material, and at least one type of friction modifying particle is disclosed. The resin material is substantially uniformly dispensed throughout the base material and a layer of a predetermined amount of the friction modifying materials forms a porous top surface on the base material.

Abstract: The present invention relates to a saturant for a base material comprising at least one type of curable resin material and at least one type of friction modifying material. The resin material and the friction modifying material form a matrix such that the resin material is substantially uniformly dispensed throughout the base material while a desired high amount of the friction modifying materials are coated.

Abstract: A friction material has a first layer of a base material and a second layer of at least one type of friction modifying particle having substantially symmetrical geometric shapes on a top surface of the base material. The second layer has an average thickness of about 30 to about 200 microns and the surface area coverage of about 80 to about 100% such that the top layer has a fluid permeability lower than the first layer.

Abstract: The present invention relates to a friction material comprising a primary layer material layer and at least a partial coating of symmetrically shaped friction modifying particles on at least one surface of the primary layer for use as an anti-shudder friction material.

Abstract: A friction material has a first layer of a base material and a second layer of at least one type of friction modifying particle having substantially symmetrical geometric shapes on a top surface of the base material. The second layer has an average thickness of about 30 to about 200 microns and the surface area coverage of about 80 to about 100% such that the top layer has a fluid permeability lower than the first layer.