Search Results for gears

Engineers at the Ford Motor Co. are using integrated computational materials engineering (ICME) tools, allowing them to accurately simulate the heat treatment of gears and predict phase transformation kinetics and distortion.

This study looks at whether adding an annealing step to the heat treating process has an effect on residual stress and distortion on hypoid gear sets. Test results indicate that the annealing heat treatment introduced between gear set soft cutting and case carburizing helped to minimize distortion.

This article compares heat treat processes and furnace types that are typically used to harden gears.

Modeling shows that achieving required gear performance in a reduced gear size is possible by changing the steel grade and heat treatment parameters during the design stage. This article describes work in which virtual computer models using DANTE software are applied to help achieve gear size reduction by including steel grade hardenability and heat treatment parameters in the design process.

The article reviews National Transportation Safety Board (NTSB) investigations into multiple Cessna 210 aircraft accidents caused by failed hydraulic actuators in the main landing gear systems. Investigators discovered a pattern of fatigue cracks in 7075-T6 aluminum actuator barrels that initiated at corrosion pits along the retaining ring groove, propagated under cyclic loading, and eventually resulted in circumferential and longitudinal fractures that leaked hydraulic fluid. Although these failures have not yet caused significant injuries, they present serious safety risks by impairing pilots' ability to fully extend and lock the landing gear. The article details the metallurgical examinations that revealed multiple crack initiation sites containing chlorine-rich aluminum oxide pits, some with cadmium remnants from the adjacent steel retainer ring, suggesting potential corrosion mechanisms. The researchers conclude that the combination of thin-walled design, stress concentrations at the retaining ring groove, susceptibility of the high-strength aluminum alloy to corrosion, and possibly inadequate inspection procedures all contributed to these premature failures, prompting ongoing work with the FAA to address the issue.

Newly developed nickel-titanium (NiTi) alloys are well suited for bearings and gears in demanding applications.

Materials used to construct spacecraft and protective gear—including the International Space Station and space suits for astronauts—must be lightweight yet strong enough to guard against cosmic dust that travels at hypervelocity. The article describes the use of glass microspheres to model cosmic dust as part of a program to enhance space apparel.

Properties and performance of lower cost “simple” alloy steels processed using induction coupled thermomagnetic processing can rival those of conventionally processed, expensive specialty alloys. This article discusses some of the demonstrated improved mechanical properties achieved for steels in a industry-government project that evaluated the viability of processing metals in a strong magnetic field.

High strength, corrosion-resistant Ferrium C64 is the culmination of a rigorous design process that bypassed extensive physical experimentation—delivering a carburizable steel with unmatched capability.

Integrated computational materials engineering has proven effective in shrinking materials development timelines and accelerating the implementation of new materials in manufactured components. This article presents examples of aerospace alloys developed using ICME techniques and provides a glimpse of future applications.

The use of braided reinforcements enables the creation of composite parts with an efficient fiber architecture and provides manufacturers with a material that results in fewer processing steps and less waste than woven alternatives. The article provides an overview of braiding machinery, braid materials, and properties of braid structures.

4D high-pressure gas quenching ensures uniform heating and quenching for precise, repeatable results while reducing distortion. This article describes the process and equipment for 4D high-pressure gas quenching and gives some examples.

Tests conducted on vacuum carburized and quenched shafts identify variables that increase distortion and the magnitude of residual stresses.

Application of heat treat simulation using the finite element method is ideal to troubleshoot, improve, and design heat treating processes. This article presents examples of heat treating simulation used in the design of a tooling component and in refining a low-pressure carburizing process.

Field assisted sintering technology (FAST) enables hybrid components for aerospace to be designed with reduced weight and without sacrificing performance. FAST can be used to produce metal, ceramic, and composite components with tailored properties via a powder metallurgy approach. In many cases, it is a one-step, cost-effective manufacturing process for production of net-shape components.

George Pfaffmann was highly regarded as a true leader and innovator in induction heating technology.

Advanced materials engineering is being used to solve component life cycle improvement challenges in extremely harsh working conditions. This article discusses examples from various industries where new materials and surface modifications are used to extend the useful life of engineering components and equipment.

For sports and recreation equipment manufacturers and sports medicine clinicians, mechanical testing is essential to optimize material performance, minimize injury, and improve recovery outcomes. This article describes some of the specialized tests used for sports equipment.

Induction heating is used to produce high quality, reliable aerospace components as well as unique combinations of engineering characteristics.

Modern, high quality induction heat treating equipment must be readily available and flexible enough to allow for easy retooling and reprogramming to process a variety of parts. This article focuses on the technical revolution taking place in induction heating, which for the first time enables preprogramming of induction equipment to change frequency and power during the heating cycle in the same manner manner as machinists have been programming CNC machines for years. This is illustrated through a case study of induction hardening a shaft-like component.