One general aspect includes a composite sprocket. The composite sprocket also includes a skeleton having a connection interface and an outer portion having a rough tooth structure. The composite sprocket also includes an overlay formed on and over the outer portion of the skeleton and may include of a precision material and forming a high precision tooth structure over the rough tooth structure.

A differential carrier case with an inserted pipe for high pressure casting may include a mold core into which a first end of a pipe is inserted, a mold core pin fixed to the mold core to fix the mold core and the first end of the pipe, a drive core pin inserted into a second end of the pipe, and a thick portion surrounding an outer portion of the pipe.

A lubrication pinion module for applying a lubricant onto a to-be-lubricated element includes a gear element having an inner surface mounted on an outer surface of a bearing element, the bearing element being mountable for rotation on a shaft and having at least one recess on its outer surface, and the gear element including a plurality of radially outwardly facing gear teeth, each of the plurality of gear teeth having first and second flanks, and at least one projection on the gear element inner surface extending into the at least one recess of the bearing element outer surface to form an interference fit with the bearing element such that the gear element rotates conjointly with the bearing element.

A method of joining two ferrous alloy component parts. The method includes hot metal casting a portion of a first ferrous alloy component part onto a first joining surface of a low carbon intermediate element; friction fitting a joining surface of a second ferrous alloy component part against a second joining surface of the low carbon intermediate element; and fusion welding with a concentrated energy source the intermediate element to the second ferrous alloy component part. The hot metal casting includes flowing a molten ferrous alloy onto the textured first joining surface, wherein the molten ally encompasses tabs extending from the first joining surface and filling apertures defined in the intermediate element. Then cooling the molten ferrous alloy such that a metallurgical and mechanical bond is formed between the portion of the first ferrous alloy component part and the first joining surface of the low carbon intermediate element.

Systems and methods in accordance with embodiments of the invention implement tailored metallic glass-based strain wave gears and strain wave gear components. In one embodiment, a method of fabricating a flexspline of a strain wave gear includes: forming a MG-based composition into a flexspline using one of a thermoplastic forming technique and a casting technique; where the forming of the MG-based composition results in a formed MG-based material; where the formed flexspline is characterized by: a minimum thickness of greater than approximately 1 mm and a major diameter of less than approximately 4 inches.

One general aspect includes a composite sprocket. The composite sprocket also includes a skeleton having a connection interface and an outer portion having a rough tooth structure. The composite sprocket also includes an overlay formed on and over the outer portion of the skeleton and may include of a precision material and forming a high precision tooth structure over the rough tooth structure.

Disclosed is a gear including a resettable metallic glass. The gear of the present disclosure includes, as a base material, a resettable metallic glass, wherein the resettable metallic glass includes at least one metal element selected from each of (a) the group consisting of Ti, Zr, and Hf and (b) the group consisting of Fe, Co, Ni, Cu, and Zn, and further includes at least one metal element to maximize the complexity in the thermodynamic enthalpy of mixing among constituent elements, thereby including multiple resetting cores in various atomic-scale cluster forms in an amorphous matrix, leading to a structure with maximized structural complexity.

A method of joining two ferrous alloy component parts. The method includes hot metal casting a portion of a first ferrous alloy component part onto a first joining surface of a low carbon intermediate element; friction fitting a joining surface of a second ferrous alloy component part against a second joining surface of the low carbon intermediate element; and fusion welding with a concentrated energy source the intermediate element to the second ferrous alloy component part. The hot metal casting includes flowing a molten ferrous alloy onto the textured first joining surface, wherein the molten ally encompasses tabs extending from the first joining surface and filling apertures defined in the intermediate element. Then cooling the molten ferrous alloy such that a metallurgical and mechanical bond is formed between the portion of the first ferrous alloy component part and the first joining surface of the low carbon intermediate element.

Systems and methods in accordance with embodiments of the invention implement tailored metallic glass-based strain wave gears and strain wave gear components. In one embodiment, a method of fabricating a flexspline of a strain wave gear includes: forming a MG-based composition into a flexspline using one of a thermoplastic forming technique and a casting technique; where the forming of the MG-based composition results in a formed MG-based material; where the formed flexspline is characterized by: a minimum thickness of greater than approximately 1 mm and a major diameter of less than approximately 4 inches.

A differential assembly is disclosed herein. The differential assembly includes a ring gear and a case. The ring gear and case may comprise dissimilar materials. The ring gear may include a ferrous material and may be overmolded by the case. The case may include a non-ferrous material. Teeth may be formed in the ring gear. The teeth may be hardened through induction heating.