# US 11,999,010 B1 · Attachment of powdered metal to powder forged or wrought materials

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- Number: US 11,999,010 B1
- Document ID: US11999010B1
- Status: Granted
- Kind: B1
- Application number: 17/167,603
- Filed: 2021-02-04
- Granted: 2024-06-04
- Earliest claimed: 2020-02-06
- Assignees: Keystone Powdered Metal Company
- Applicants: Peter Stauffer; Barry Kline
- Inventors: Peter Stauffer; Barry Kline
- Web page: https://patentgrep.com/patent/US11999010B1

## CPC

- B23K 26/32: taking account of the properties of the material involved
- B23K 2101/008: {Gears}
- B23K 2103/00: Materials to be soldered, welded or cut
- B23K: SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM

## Abstract

This invention relates to a method for manufacturing a metal part which comprises attaching a powder forged or wrought outer raced ID splined plate to a powdered metal inner splined connection gear, wherein the outer raced ID splined plate incorporates a female ID profile on the race, wherein the inner splined connection gear contains a mail OD profile on the exterior of the part, and wherein the splined plate and the splined connection gear are attached together by (1) sinter brazing, (2) laser brazing, (3) laser welding, (4) sintering a mechanical joint, or (5) staking. In practicing this method a tight mechanical joint is formed between the splined plate and the splined connection gear which can be made of highly dissimilar materials, such as a wrought metal and a sintered powder metal.

## Claims

### Claim 1

A method of manufacturing a metal part which comprises (1) providing an external component and an internal component, wherein the external component has an external profile which includes a female inside diameter profile, and wherein the internal component has an internal profile which includes a male outside diameter profile, wherein the external component is comprised of a forged powder metal or a wrought metal and wherein the internal component is comprised of a sintered powder; (2) positioning the male outside diameter profile of the internal component within the female inside diameter profile of the external component; and (3) affixing the external component and the internal component together by sinter brazing or laser brazing.

### Claim 2 (depends on 1)

The method of claim 1 wherein the external component is comprised of a wrought metal.

### Claim 3 (depends on 1)

The method of claim 1 wherein the external component is comprised of a forged powder metal.

### Claim 4 (depends on 1)

The method of claim 1 wherein the external component and the internal component are affixed together by sinter brazing.

### Claim 5 (depends on 1)

The method of claim 1 wherein the external component and the internal component are affixed together by laser brazing.

### Claim 6 (depends on 1)

The method of claim 1 wherein the metal part is a toroidal part, wherein the external component is an outer race, and wherein the internal component is inner splined connection gear.

### Claim 7 (depends on 6)

The method of claim 6 wherein the outer race has a female inside diameter profile.

### Claim 8 (depends on 1)

The method of claim 1 wherein metal part is an inner splined connection gear.

### Claim 9 (depends on 8)

The method of claim 8 wherein the inner splined connection gear has a male connector.