Abstract: A method of forming a welded connection between a hub and a plate component in a transmission assembly is provided. The method includes providing the plate component which includes a radially extending portion and an opening in a connection region to the hub, forming a flare bevel with an axial extension that extends beyond a projection of a thickness of the radially extending portion of the plate component at the opening, locating the plate component with the flare bevel and at least a portion of the axial extension on the hub, welding in a recess formed between the flare bevel and the hub to connect the plate component to the hub with the weld, and removing at least a portion of the axial extension after the welding.

Abstract: A method of forming a welded connection between a hub and a plate component in a transmission assembly is provided. The method includes providing the plate component which includes a radially extending portion and an opening in a connection region to the hub, forming a flare bevel with an axial extension that extends beyond a projection of a thickness of the radially extending portion of the plate component at the opening, locating the plate component with the flare bevel and at least a portion of the axial extension on the hub, welding in a recess formed between the flare bevel and the hub to connect the plate component to the hub with the weld, and removing at least a portion of the axial extension after the welding.

Abstract: A method of assembling a pilot to a torque converter cover is provided with the method including: (a) providing the pilot having an annular projection in a connection region; (b) forming a torque converter cover of a torque converter with a complementary recess or annular groove to the annular projection in a mating connection region; (c) positioning the pilot on the torque converter cover with the annular projection at least partially received in the complementary recess or annular groove; and (d) applying force and energy to the pilot to weld the pilot to the torque converter cover. A torque converter assembly is also provided.

Abstract: A method of assembling a pilot to a torque converter cover is provided with the method including: (a) providing the pilot having an annular projection in a connection region; (b) forming a torque converter cover of a torque converter with a complementary recess or annular groove to the annular projection in a mating connection region; (c) positioning the pilot on the torque converter cover with the annular projection at least partially received in the complementary recess or annular groove; and (d) applying force and energy to the pilot to weld the pilot to the torque converter cover. A torque converter assembly is also provided.

Abstract: A torque converter including: a cover arranged to receive torque; an impeller; a turbine in fluid communication with the impeller; a stator assembly; a lock-up clutch including an axially displaceable piston plate; a vibration damper including an output flange, a retainer plate, and a spring directly engaged with the output flange and retainer plate; a first combination component having a first single unified structure including a first section forming a pilot hub located radially inward of the cover and non-rotatably connected to the cover, and a second section forming a seal plate of the lock-up clutch; and a second combination component having a second single unified structure including a third section forming a shell of the turbine, and a fourth section forming a cover plate of the vibration damper, the fourth section directly engaged with the spring and non-rotatably connected to the retainer plate.

Abstract: A torque converter, including: a cover arranged to receive torque and supported for rotation around an axis of rotation; an impeller including an impeller shell connected to the cover and at least one impeder blade; a turbine in fluid communication with the impeller and including a turbine shell and at least one turbine blade; and a stator assembly including a stator including a plurality of stator blades, a side plate including a radially outer surface defining a slot, a one-way clutch axially disposed between the stator and the side plate, and a washer including an annular body portion in contact with the side plate, and an axial protrusion extending past the annular body portion in a first axial direction parallel to the axis of rotation, and disposed in the slot.

Abstract: A torque converter includes an impeller and a cover rotationally fixed to the impeller. The cover has opposing inner and outer surfaces and a through hole extending from the inner surface to the outer surface. A stud is attached to the cover. The stud has a head and a shank extending from the head. The head defines an annular projection circumscribing the shank and raised from the head. The stud is disposed on the cover with the shank extending through the hole to project from the outer surface and with the head being connected to the cover by coalescence between the annular projection and the inner surface creating a hermetic seal around the hole.

Abstract: A torque converter in a vehicle includes a cover for the torque converter, wherein the cover includes a front surface and a back surface and a stud including a head and an end with a shaft therebetween passing through an opening of a flex plate, wherein the head includes a top surface and a bottom surface, wherein the top surface include an annular projection penetrating the front surface of the cover and the bottom surface is adjacent the shaft.

Abstract: A torque converter in a vehicle includes a cover for the torque converter, wherein the cover includes a front surface and a back surface and a stud including a head and an end with a shaft therebetween passing through an opening of a flex plate, wherein the head includes a top surface and a bottom surface, wherein the top surface include an annular projection penetrating the front surface of the cover and the bottom surface is adjacent the shaft.

Abstract: A torque converter includes an impeller and a cover rotationally fixed to the impeller. The cover has opposing inner and outer surfaces and a through hole extending from the inner surface to the outer surface. A stud is attached to the cover. The stud has a head and a shank extending from the head. The head defines an annular projection circumscribing the shank and raised from the head. The stud is disposed on the cover with the shank extending through the hole to project from the outer surface and with the head being connected to the cover by coalescence between the annular projection and the inner surface creating a hermetic seal around the hole.

Abstract: A torque converter that includes an impeller hub with an elongated member portion including a beveled-surface running radially and axially outward from an impeller assembly from a first end in contact with an impeller assembly to a second end, wherein the impeller hub further includes a weld at the beveled-surface and in contact with the impeller assembly.

Abstract: A method of forming an impeller for a torque converter is provided. The method includes providing an impeller shell including a back axial surface for facing away from an interior of the torque converter, providing an impeller hub including an outer circumferential surface and forming a weld joining the impeller shell and the impeller hub. The weld is contiguous with the back axial surface of the impeller shell. The weld is also contiguous with the outer circumferential surface of the impeller hub. The weld includes a root where the impeller shell and the impeller hub meet the weld. The method also includes machining the root. An impeller for a torque converter is also provided.

Abstract: A method of forming an impeller for a torque converter is provided. The method includes providing an impeller shell including a back axial surface for facing away from an interior of the torque converter, providing an impeller hub including an outer circumferential surface and forming a weld joining the impeller shell and the impeller hub. The weld is contiguous with the back axial surface of the impeller shell. The weld is also contiguous with the outer circumferential surface of the impeller hub. The weld includes a root where the impeller shell and the impeller hub meet the weld. The method also includes machining the root. An impeller for a torque converter is also provided.