Abstract: An axle assembly that includes a housing, an input pinion, a ring gear, an angular contact bearing, and a differential assembly. The input pinion has a plurality of pinion teeth and is received in the housing for rotation about a first axis. The ring gear, which is received in the housing, is a bevel gear having ring gear teeth that define a pitch angle and are meshingly engaged with the pinion teeth. The angular contact bearing supports the ring gear for rotation on the housing about a second axis that is transverse to the first axis. The angular contact bearing has a first race, which is integrally formed into the ring gear, a second race, and a plurality of bearing balls disposed between the first and second races. The differential assembly has a differential case that is mounted to the ring gear for rotation therewith.

Abstract: An assembly that includes a tube mount, a tube, a first fillet weld, and a second fillet weld. The tube mount has a tubular side wall, a plurality of circumferentially spaced apart notches formed on a first end of the tubular side wall, and a securing aperture formed through the tubular side wall. The notches form a plurality of teeth. The tube is received into the tube mount. The first fillet weld couples the tube to the tube mount. The first fillet weld is formed about a perimeter the first end such that each of the first welds is formed substantially completely over the entirety of the teeth. The second fillet weld couples the tube to the tube mount. The second fillet weld is formed about a perimeter of the securing aperture such that the second fillet weld is formed substantially completely over an inside perimeter of the securing aperture.

Abstract: A rear drive module for an all-wheel drive vehicle. The rear drive module includes a disconnect clutch, a differential assembly and a hollow shaft. The disconnect clutch has a first clutch member, which is coupled to the spool for rotation therewith, and a second clutch member. The differential assembly includes a differential case. The hollow shaft is coupled to the differential case for rotation therewith and is configured to transmit rotary power in a power path between the disconnect clutch and the differential assembly.

Abstract: A power transmitting component with a housing, a shaft and a seal. The housing has a wall member, a shaft bore, and a shield wall. The shaft bore is formed through the wall member. The shield wall is coupled to and extends outwardly from the wall member. The shield wall is formed about the shaft bore and defines a drain spout. The shaft is received through the shaft bore. The seal is received in the shaft bore and sealingly engages the housing and the shaft. The drain spout is configured to drain liquid from a space that is radially inward of the shield wall when the power transmitting component is disposed in a predetermined orientation.

Abstract: An actuator that causes a mode clutch to shift between an engaged position and a disengaged position is provided. The actuator comprises a motor having an output. A shift cam is caused to rotate based on the output of the motor. The shift cam has a cam profile surface. A cam follower rides along the cam profile surface upon rotation of the shift cam. Movement of the cam follower causes movement of a mode fork resulting in the mode clutch shifting between the engaged and disengaged positions. A sensor outputs a voltage to a controller based on a physical location of the cam follower. The controller activates the motor based on the voltage.

Abstract: A disconnectable driveline arrangement for an all-wheel drive vehicle includes a power take-off unit having a disconnect mechanism, and a drive module having a torque transfer device and a limited slip clutch assembly.

Abstract: A vehicle with a primary driveline that is configured to distribute rotary power to a first set of vehicle wheels and a power transmitting device that can be selectively operated to transmit rotary power to a secondary driveline. The power transmitting device has an input member, which is driven by the primary driveline, and an output member that is selectively coupled to the input member to receive rotary power therefrom. The secondary driveline comprises a differential, a pair of shafts, and a side shaft coupling that selectively interrupts power transmission between the differential and one of the shafts.

Abstract: A disconnectable all-wheel drive system for motor vehicles having a multi-speed power take-off unit and a multi-speed rear drive module.

Abstract: A disconnectable driveline arrangement for an all-wheel drive vehicle includes a power take-off unit having a disconnect mechanism, and a drive module having a torque transfer device and a limited slip clutch assembly.

Abstract: A disconnectable driveline arrangement for an all-wheel drive vehicle includes a power take-off unit having a disconnect mechanism, and a drive module having a torque transfer device and a limited slip clutch assembly.

Abstract: A vehicle with a primary driveline that is configured to distribute rotary power to a first set of vehicle wheels and a power transmitting device that can be selectively operated to transmit rotary power to a secondary driveline. The power transmitting device has an input member, which is driven by the primary driveline, and an output member that is selectively coupled to the input member to receive rotary power therefrom.

Abstract: A vehicle driveline that includes an input member, a multi-speed transmission, a first differential assembly, a first bevel ring gear and a mode clutch that are disposed axially along a rotational axis of the input member. The multi-speed transmission includes a range collar that is axially movable along the input member axis.

Abstract: A power transmitting component with a housing, a shaft and a seal. The housing has a wall member, a shaft bore, and a shield wall. The shaft bore is formed through the wall member. The shield wall is coupled to and extends outwardly from the wall member. The shield wall is formed about the shaft bore and defines a drain spout. The shaft is received through the shaft bore. The seal is received in the shaft bore and sealingly engages the housing and the shaft. The drain spout is configured to drain liquid from a space that is radially inward of the shield wall when the power transmitting component is disposed in a predetermined orientation.

Abstract: A flexible seal having an X-shaped cross section that forms four contact points on four contact surfaces of two opposed seal slots. The flexible seal is used for a component in which the two seal slots undergo a large deflection such that the opposed slots are not aligned and a rigid seal will not form an adequate seal. The flexible seal can be used in a component of a combustor or a turbine in a gas turbine engine where opposed seal slots undergo the large deflection during operation.

Abstract: A micro gas turbine engine in which the turbine rotor blades are formed as an integral bladed rotor with cooling air passages formed within the blades and the rotor disk by an EDM process. an adjacent stator vane includes an air riding seal with an air cushion supplied through the vanes to provide cooling, and where the air cushion is then passed into the turbine blades and rotor disk to provide cooling for the turbine blades. With cooling of the turbine blades, higher turbine inlet temperatures for micro gas turbine engines can be produced.

Abstract: An axial flow compressor blade with a cavity formed within the blade tip region and connected by an array of holes onto the pressure side surface of the blade in the tip region so that compressed gas will flow into the cavity, and the cavity is connected by a row of tip slots arranged along the blade tip along the pressure side tip corner to discharge the compressed gas from within the cavity out onto the blade tip toward the oncoming compressed gas flow over the blade tip to reduce or eliminate any boundary layer formation and to reduce blade tip leakage flow.

Abstract: An air cooled turbine airfoil, such as a rotor blade, with a sequential impingement cooling circuit that provides a high level of cooling with a low amount of cooling air. The airfoil is formed of a spar and shell construction in which the spar is formed from a series of alternating layers that form the cooling circuit with the shell forming the gap for the impingement cooling channels. Two different layers form the impingement cooling channels with a third layer being a separation layer. The impingement cooling circuit includes a first impingement channel to cooling a forward half of the pressure side wall, a second impingement cooling channel to cool the aft half of the pressure side wall, a third impingement cooling channel to cool a forward section of the suction side wall, and a fourth impingement cooling channel to cool the aft section of the suction side wall.

Abstract: An air cooled turbine airfoil having micro cooling air passages formed within the airfoil that is of such size that the present day investment coating process cannot be used. The internal cooling air features of the airfoil are formed using the Tomo Lithographic Molding (TLM) process. The TLM process is a low pressure casting process that can produce precise micro-features integral to macro-scale structures using any of the exotic alloys or other metallic materials currently being used in airfoil production. The normal internal cooling air passages as well as very small features such as trip strips, pin fins, dimples, pedestals and enclosed passages such as film holes can be produced using the TLM process.

Abstract: A powertrain with a disconnecting rear drive axle generally includes a prime mover including an output that rotates about a rotational axis. A transmission includes an output that rotates about a rotational axis. The rotational axes of the outputs are substantially parallel to a longitudinal axis of the powertrain. A front driveline is operable to direct rotary power from the prime mover to front vehicle wheels. A rear driveline includes a propeller shaft that provides rotary power to a first shaft member and a second shaft member through a pinion and a ring gear. The first shaft member and the second shaft are operable to connect to rear vehicle wheels. A power switching mechanism has an engaged condition and a disengaged condition. The power switching mechanism is operable to direct the rotary power from the transmission to the rear driveline in the engaged condition. A torque transfer device has an engaged condition and a disengaged condition.

Abstract: An axle assembly having an axle assembly with first and second sumps for holding a lubricant. A rotating ring gear associated with a differential can rotate through the lubricant in the first sump to cause a portion of the lubricant to cling to the ring gear. A portion of the lubricant that has clung to the ring gear can be removed from the ring gear and transferred to the second sump. The lubricant in the second sump can be drained to lubricate teeth of a pinion that is in meshing engagement with the ring gear and/or to lubricate bearings that support the pinion. A related method is also provided.