Gkn Sinter Metals Gmbh

Keystone Powdered Metal Company

Timothy E Geiman

Joel H Mandel

Alfred J Chiesa

Henry James Knott

Ian W Donaldson

Donald J Phillips

Virgiliu-Adrian Savu

David E Lenhart

Kevin A Bauer

Ray K Williams

Brandon A Nichols

Allan Keeble

Ronald Lee Trosin

Timothy Laughlin

Michael P Marra

The present invention provides a method of manufacturing combination gears and compound gears having challenging geometries using powder metal technology. This method allows for the production of combination gears and compound gears having any combination of straight or helical gear faces even in cases where the smaller gear intersects the flange of the larger gear creating an inside corner. The subject invention more specifically relates to a method for manufacturing a combination gear or a compound gear having a larger diameter gear face and a smaller diameter gear face, said method comprising molding a powder metal composition into a green preform having the smaller diameter gear face and a larger diameter cylindrical blank face, and subsequently machining the larger diameter cylindrical blank face into the larger diameter gear face.

Method for manufacturing combination or compound gears

A differential assembly includes one or more NVH-modifying elements that alter and/or reduce at least one of a noise, vibration, and harshness emitted from the differential assembly. The NVH-modifying element(s) are placed in engagement with the side gears of the differential assembly to modify and/or reduce the NVH of the differential assembly.

NVH modification for differential assembly

A forged composite inner race for a constant velocity joint is forged from a composite preform compact including a first powder metal material and a second powder metal material. The forged composite inner race includes a plurality of ball tracks formed on an outer section of the forged composite inner race with corresponding lands between adjacent ball tracks and an axially-extending splined opening formed in an inner section of the forged composite inner race. The outer section comprises the first powder metal material in a higher concentration than the second powder metal material and the inner section comprises the second powder metal material in a higher concentration than the first powder metal material.

Forged composite inner race for a CVJ

A forged composite powder metal part, such as a CVJ inner race or bevel gear, and method of making the same are disclosed. The forged composite powder metal part includes a outer section concentrated with a first powder metal material, a inner section concentrated with a second powder metal material and a variable boundary profile between the materials of the two sections. For example, in a forged CVJ inner race, the different materials can provide improved wear resistance in the ball tracks and improved spline performance. As another example, in a forged bevel gear, the different materials can be used to create a continuous variable boundary profile that defines the depth of a harder layer over the teeth.

Forged composite powder metal part and method of making same

A component () is adapted for contact with a mating component () during attachment of the components to one another to form a related assembly in which a deformable pad () or pads improve stress distribution. The component includes a body having an interface surface in which the body is adapted to be contacted with the mating component at the interface surface of the body. One or more deformable pads are formed in the interface surface. Each deformable pad has a top surface that is offset outwardly from the interface surface relative to the body and a groove surrounding the deformable pad that is offset inwardly from the interface surface relative to the body.

Component with deformable pads

A process for manufacturing connecting rods is provided which comprises the steps of compacting, sintering, and powder forging a powder metal comprising a carbon source and a prealloyed powder consisting essentially of iron and copper. The connecting rods made from this process have sufficient hardness and strength to be used in an engine and do not require any additional quenching or tempering.

Prealloyed copper powder forged connecting rod

A differential assembly, bevel gears for the assembly, and a method of making the bevel gears are disclosed. The bevel gears have a form which provides for high power density transfer.

Powder forged differential gear

A forged composite gear and a method of making a forged composite powder metal gear. The forged composite gear includes a plurality of teeth extending from a core, a first section having a first powder metal material, a second section having a second powder metal material and a variable boundary profile. The variable boundary profile is formed between the first section and the second section, whereby said variable boundary profile exhibits greater tooth wear resistance on the teeth and greater impact resistance in the core.

Method of forming composite powder metal gear

A gear and a method of making a forged powder metal gear having a plurality of teeth and a variable case depth profile forged in the plurality of teeth. Each tooth of the plurality of teeth has a first surface and a tooth root. A variable case depth profile is formed in each tooth of the plurality of teeth, whereby the variable case depth profile exhibits greater tooth wear resistance on the first surface and greater impact resistance in the tooth root.

Variable case depth powder metal gear and method thereof

A method for obtaining a selectively non-carburized powdered metal part. The steps include compacting, sintering, removing, forging and cooling. A metal powder is compacted to form a preform having at least one first surface in which a forged part is required to have a case depth and at least one second surface in which a carburized portion is required to be removed prior to forging. The preform is then sintered and carburized. After carburizing the at least one second surface of the preform is removed and subsequently forged and cooled. The forged part has at least one second surface having improved post forging properties and at least one first surface having improved performance features. A part made from the present method is also provided.

Forged carburized powder metal part and method

A presently-preferred process for manufacturing a connecting rod comprises placing a heated preform suitable for being formed into the connecting rod into a closed forge die, and forging the preform in a first forging operation while the preform is at a forging temperature to form an as-forged connecting rod having vertical flash extending therefrom. The presently-preferred process further comprises placing the as-forged connecting rod in a second forge die while the as-forged connecting rod is at a temperature substantially equal to the forging temperature, and forging the vertical flash in a second forging operation. The presently-preferred process also comprises removing the as-forged connecting rod from the second forge die, and machining the as-forged connecting rod to predetermined dimensions.

Growing community of inventors

South Lyon, MI, United States of America

Timothy E Geiman