Award: Award of Distinction
Year: 2001
Category: Ferrous
Market Segment: Automotive

Description:
The award was given to a transmission carrier consisting of a flanged hub and spider that are sinter brazed into one unit which has a typical density of 7.0 g/cm³. Typical mechanical properties are: ultimate tensile strength 483MPa (70,000 psi), yield strength 393MPa (57,000 psi), and hardness of 70 HRB. The overdrive carrier operates in a Ford 4R100 transmission installed in F series trucks such as the F-150, F-150 super duty, and Excursion SUV. The carrier has the longest hub of any automotive PM carrier. With a spline length of about 44 mm (1.73in.) After sintering, the part is sized, machined and deburred. The ID spline is net formed. The pinion shaft holes are machined along with the spider face and counterbore diameters and the zero face. The pinion shaft cross holes are also drilled. Ford Powertrain put the carrier through validation tests such as high cycle/low load fatigue testing, vehicle durability testing in cars and light trucks, ultimate torque, and a bond strength static test. PM offered significant cost savings over casting.