Abstract: An axle housing for an axle assembly of a vehicle includes a pinion portion and a differential portion. The differential portion rotatably supports a differential gear assembly. A pinion insert has a first and second bearing pockets and is disposed in the pinion portion of the axle housing at least partially forming a bore through which a pinion shaft rotates. A first bearing is disposed in the first bearing pocket of the pinion insert and a second bearing is disposed in the second bearing pocket of the pinion insert. The pinion insert is manufactured from a material having a higher stiffness than the cast metal alloy of the axle housing.

Abstract: An axle carrier housing includes a center housing defining an internal chamber, a pinion nose extending from the center housing to a housing front end, the pinion nose defining a pinion chamber configured to house a pinion shaft assembly, the housing front end defining a shaft opening having a central axis, and a first axle tube extending from the center housing to a housing first side defining a first axle tube opening having a first axle axis that is generally perpendicular to the central axis. A second axle tube extends from the center housing to a housing second side that is opposite the housing first side, the second axle tube defining a second axle tube opening having a second axle axis that is concentric with the first axle axis. First and second transverse webs extend angularly from the pinion nose and the center housing.

Abstract: An axle carrier housing includes a center housing defining an internal chamber, a pinion nose extending from the center housing to a housing front end, the pinion nose defining a pinion chamber configured to house a pinion shaft assembly, the housing front end defining a shaft opening having a central axis, and a first axle tube extending from the center housing to a housing first side defining a first axle tube opening having a first axle axis that is generally perpendicular to the central axis. A second axle tube extends from the center housing to a housing second side that is opposite the housing first side, the second axle tube defining a second axle tube opening having a second axle axis that is concentric with the first axle axis. First and second transverse webs extend angularly from the pinion nose and the center housing.

Abstract: An improved aluminum alloy stock material is provided for use in a tubeplate-and-center type evaporator within an automobile air conditioning system. The improved aluminum alloy stock contains a unique aluminum alloy core material which is clad on both sides with an appropriate aluminum-silicon brazing alloy. The inventive aluminum alloy core material is characterized by the presence of boron in amounts sufficient to inhibit the formation of copper-rich precipitates in the grain boundaries of the alloy, so as to enhance the ability of the alloy to resist intergranular corrosion. The alloy is also characterized by a higher copper concentration and lower manganese and titanium concentrations as compared to conventional aluminum alloys used in these types of aluminum alloys.

Abstract: A method is provided for forming a metallurgical bond between an aluminum-base insert and an aluminum-base casting material during a casting process, wherein the method entails wetting the oxide surface of the insert, coating the surface with a metallurgically compatible material, and raising the temperature of the insert to reduce the temperature gradient between the insert and the casting material. The insert is dipped into a molten zinc-base alloy which includes about 2 to about 10 weight percent aluminum. The zinc-base alloy coats the insert and remains on the surface of the insert until a molten casting material is introduced. As a result, the surface of the coated insert is nearly oxide-free. The aluminum content in the zinc-base alloy is preferably about 4 to about 6 weight percent of the zinc-base alloy. The zinc-base alloy also preferably contains between about 0.25 and 0.35 weight percent magnesium for the purpose of weakening the oxide film layer on the insert.

Abstract: An improved aluminum-silicon alloy having relatively substantial additions of tin and bismuth is provided which is particularly wear-resistant and sufficiently self-lubricating so as to be suitable for use in a wearing component even when poorly lubricated. The relatively high tin and bismuth additions within the alloy cooperate with the other elemental additions so as to provide a sufficiently low friction bearing surface (or self-lubricity) which significantly enhances the wear resistant properties of the alloy. In particular, the preferred aluminum alloy is used to form a socket plate which receives high strength steel bearing members within a compressor unit of an automobile air conditioning system. The improved aluminum alloy minimizes wear and alleviates galling of the socket plate during use.

Abstract: An improved aluminum-silicon-copper alloy having a relatively high level of bismuth is provided which is particularly wear-resistant and sufficiently self-lubricating so as to be suitable for use in a wearing component even when poorly lubricated. The relatively high bismuth level within the alloy cooperates with the other elemental additions so as to provide a sufficiently low friction bearing surface (or self-lubricity), which significantly enhances the wear resistant properties of the alloy. In particular, the preferred aluminum alloy is suited for use in a socket plate which receives high strength steel bearing members within a compressor unit of an automobile air conditioning system. The improved aluminum alloy should minimize wear and alleviate galling of the socket plate during use. In addition, the improved aluminum alloy should have sufficient strength and ductility so as to permit swaging of the socket plate formed from the alloy around a balled end of the high strength steel bearing member.

Abstract: An improved eutectic aluminum-silicon alloy having a relatively high level of bismuth is provided which is particularly wear-resistant and sufficiently self-lubricating so as to be suitable for use in a wearing component even when poorly lubricated. The relatively high bismuth level within the alloy cooperates with the other elemental additions so as to provide a sufficiently low friction bearing surface (or self-lubricity), which significantly enhances the wear resistant properties of the alloy. In addition, the preferred alloy also has relatively substantial additions of both nickel and copper, which results in the homogeneous distribution of hard wear resistant nickel and copper phases throughout. The improved aluminum alloy should minimize wear and alleviate galling during use.