Abstract: A ladle, process, and system for casting an aluminum-based alloy includes a casting ladle. The casting ladle includes a cup and the cup defines an opening. The ladle also includes an ultrasonic transducer including an end immersed in the cup, wherein the cup exhibits a first depth and the ultrasonic transducer is immersed in the cup at a second depth in a range of 5 percent to 100 percent of the first depth. An aluminum-based alloy melt is introduced into an opening of a casting ladle, an ultrasonic transducer immersed in the aluminum-based alloy melt is activated, and the aluminum-based alloy melt is transferred onto a casting surface.

Abstract: A friction clutch assembly for an automatic transmission, a friction clutch plate, and a method of forming a friction clutch plate are provided. The method includes providing a friction material layer for a face of the friction clutch plate and cutting the friction material layer with a laser beam to form a plurality of grooves within the friction material layer. In one version, a friction plate for the friction clutch assembly includes an annular core plate having first and second opposed faces and defining an outer edge and an inner edge. Friction material is affixed to at least one of the first and second opposed faces. The friction material defines a plurality of grooves within the friction material, each groove being bordered by friction material having a ridge. The cross-section of the ridge has a corner having a radius of curvature that is less than 300 microns.

Abstract: A friction clutch assembly for an automatic transmission, a friction clutch plate, and a method of forming a friction clutch plate are provided. The method includes providing a friction material layer for a face of the friction clutch plate and cutting the friction material layer with a laser beam to form a plurality of grooves within the friction material layer. In one version, a friction plate for the friction clutch assembly includes an annular core plate having first and second opposed faces and defining an outer edge and an inner edge. Friction material is affixed to at least one of the first and second opposed faces. The friction material defines a plurality of grooves within the friction material, each groove being bordered by friction material having a ridge. The cross-section of the ridge has a corner having a radius of curvature that is less than 300 microns.

Abstract: A method for densifying a surface of a powder metal part, includes blending a plurality of powdered metals to form a powder metal blend, actuating an upper punch and a lower punch to apply pressure to the powder metal blend to compact the powder metal blend, sintering the compacted powder metal blend in an oven, forming the compacted powdered metal blend into the powder metal part, heating a portion of the surface of the powder metal part, and densifying the portion of the surface of the powder metal part for a predetermined period of time after the portion of the powder metal part is heated to a predetermined temperature.

Abstract: The present invention provides improved clutch plates for use in wet friction pack clutches and brakes which exhibit greatly reduced flutter particularly at high rotational speeds. Friction clutches and brakes include a first plurality of circular clutch plates or discs coupled to a first member comprising a metal core plate having bands of friction material affixed to both faces. These clutch plates are interleaved with a second plurality of circular metal reaction plates which are coupled to a second member. The metal core plate of the first plurality of clutch plates includes a plurality of radial slots spaced about the core plate which extend inwardly a portion of the radial width of the clutch core plate. Different numbers of slots, different spacings and different configurations of slots provide reduced plate flutter with varying thicknesses of core plates and ranges of rotational speeds.

Abstract: The present invention provides improved clutch plates for use in wet friction pack clutches and brakes which exhibit greatly reduced flutter particularly at high rotational speeds. Friction clutches and brakes include a first plurality of circular clutch plates or discs coupled to a first member comprising a metal core plate having bands of friction material affixed to both faces. These clutch plates are interleaved with a second plurality of circular metal reaction plates which are coupled to a second member. The metal core plate of the first plurality of clutch plates includes a plurality of radial slots spaced about the core plate which extend inwardly a portion of the radial width of the clutch core plate. Different numbers of slots, different spacings and different configurations of slots provide reduced plate flutter with varying thicknesses of core plates and ranges of rotational speeds.

Abstract: A friction clutch pack exhibiting improved high speed stability includes a first plurality of friction plates or discs preferably having friction material on both faces interleaved with a second plurality of thicker reaction plates or discs. The friction plates comprise a formed core plate having multiple obliquely oriented or angularly offset sinusoidal waves. Male splines around the periphery of each friction plate engage complementary splines on a cylindrical housing. The reaction plates are flat and thicker than the friction plates and include female splines around an inner opening which engage complementary splines on a shaft or quill.

Abstract: A friction clutch pack exhibiting improved high speed stability includes a first plurality of friction plates or discs preferably having friction material on both faces interleaved with a second plurality of thicker reaction plates or discs. The friction plates comprise a formed core plate having multiple obliquely oriented or angularly offset sinusoidal waves. Male splines around the periphery of each friction plate engage complementary splines on a cylindrical housing. The reaction plates are flat and thicker than the friction plates and include female splines around an inner opening which engage complementary splines on a shaft or quill.

Abstract: A friction plate assembly for use in a dry clutch, the friction plate assembly includes a hub and support member, a first friction disc, a second friction disc, and a plurality of silicone-based adhesive beads disposed between each of the first friction disc and the second friction disc. The adhesive beads are disposed in a pattern designed to create a cooling air pathway from the interior of the friction plate assembly to the exterior.

Abstract: A bi-directional overrunning clutch assembly employed in connection with a reduced capacity low friction clutch to provide low and reverse gears in a transmission. The clutch assembly including an inner race, an outer race, and engagement members supported therebetween. The inner race is operatively coupled to the transmission casing and the outer race is operatively coupled to the ring gear of the gear set as well as the inner race of the friction clutch assembly. The clutch assembly further includes at least one actuating cam. The actuating cam operates to actuate the engagement members to provide four separate modes of operation between the inner and outer races of the clutch assembly.

Abstract: A bi-directional overrunning clutch assembly including an inner race, an outer race, and engagement members supported therebetween. The clutch assembly further includes at least one actuating cam. The actuating cam operates to actuate the engagement members to provide four separate modes of operation between the inner and outer races of the clutch assembly.

Abstract: Pursuant to the control strategy of the present invention, torque load may be shared between the low/reverse friction clutch and a one-way clutch to effect low and reverse gear ratios in a transmission. This may be accomplished by engaging the friction clutch during vehicle launch and keeping it engaged until the peak torque has passed. Once the peak torque has been passed, the load capacity of the friction clutch can be reduced to zero. In this operational mode, the one-way clutch is acting to support the remaining drive torque. Thus, with only the one-way clutch carrying a load at the time of the up-shift from first to second gear, a non-synchronous shift can be affected. In this way, the control strategy acts to share the torque load between the low/reverse brake and the low one-way clutch, thereby allowing a reduced capacity, lower spin-loss one-way clutch design.

Abstract: A clutch assembly (10) having an inner race (12), an outer race (14), and an engagement mechanism (16) disposed between the inner and outer races. The engagement mechanism (16) is operable to move between a disengaged position wherein the inner and outer races may freely rotate in one direction relative to one another and an engaged position wherein in the inner and outer races are locked so as to translate torque therebetween in the opposite rotational direction. The inner race (12) and outer race (14) may be defined by a plurality of plates (18, 22) and layers of elastomer (20, 24) that are disposed between adjacent plates in laminated fashion. The inner race and/or outer race may further include at least one bearing surface through which a force may be translated. The bearing surface is defined by a plurality of plates (70, 76) that are offset relative to an adjacent plate by a predetermined distance.

Abstract: A bi-directional overrunning clutch assembly including an inner race, an outer race, and engagement members supported therebetween. The clutch assembly further includes at least one actuating cam. The actuating cam operates to actuate the engagement members to provide four separate modes of operation between the inner and outer races of the clutch assembly.

Abstract: A clutch assembly (10) having an inner race (12), an outer race (14), and an engagement mechanism (16) disposed between the inner and outer races. The engagement mechanism (16) is operable to move between a disengaged position wherein the inner and outer races may freely rotate in one direction relative to one another and an engaged position wherein in the inner and outer races are locked so as to translate torque therebetween in the opposite rotational direction. The inner race (12) and outer race (14) may be defined by a plurality of plates (18, 12) and layers of elastomer (20, 24) that are disposed between adjacent plates in laminated fashion. The inner race and/or outer race may further include at least one bearing surface through which a force may be translated. The bearing surface is defined by a plurality of plates (70, 76) that are offset relative to an adjacent plate by a predetermined distance.

Abstract: A friction plate and friction facing material assembly includes a friction plate having a waved or sinusoidal annular shape and friction material mounted on at least a portion of the friction plate. The waved friction plate defines a plurality of upwardly extending sections having no friction material thereon.

Abstract: A friction plate and friction facing material assembly includes a friction plate having a waved or sinusoidal annular shape and friction material mounted on at least a portion of the friction plate. The waved friction plate defines a plurality of upwardly extending sections having no friction material thereon.

Abstract: A friction device includes drive and driven members rotatable about a common axis and defining a housing therebetween in which a piston assembly is supported and an expandable chamber is defined. A clutch pack is interposed between the drive and driven members and has separation plates interleaved with friction plates. The piston assembly is adapted to move among disengaged, pre-staged, and engaged positions wherein the friction plates are disposed in non-contacting, proximate contacting, and contacting relationship, respectively, with the separation plates. In the engaged position, the piston assembly is disposed forcing such contacting relationship to actuate the clutch pack to connect the drive and driven members.

Abstract: A friction device includes drive and driven members rotatable about a common axis and defining a housing therebetween in which a piston assembly is supported and an expandable chamber is defined. A clutch pack is interposed between the drive and driven members and has separation plates interleaved with friction plates. The piston assembly is adapted to move among disengaged, pre-staged, and engaged positions wherein the friction plates are disposed in non-contacting, proximate contacting, and contacting relationship, respectively, with the separation plates. In the engaged position, the piston assembly is disposed forcing such contacting relationship to actuate the clutch pack to connect the drive and driven members.

Abstract: A friction device includes piston assembly is responsive to the pressure of fluid in an expandable chamber to move between disengaged and engaged positions thereby actuating a clutch pack to connect and disconnect drive and driven members. The piston assembly includes a main body having an outer ring annularly disposed about the main body. The outer ring includes at least one orifice extending therethrough. The outer ring is movable between a first position wherein the orifice is closed and the drive and driven members are disconnected and a second position where the orifice is open to allow the flow of pressurized fluid through the orifice and from the outer diameter of the clutch pack between the adjacent plates and disks to the inner diameter of the clutch pack to cool same when the drive and driven members are connected.