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For the ring gear, would case hardening still be the correct choice? Or is the thickness small enough that through hardened material is better?

I am looking at making a few different involute tooth planetary gearsets, predominantly using EDM machining, with a post EDM surface treatment (to remove re-casting). I cannot say for sure that "production" will move away from EDM to be certain, but the process may move to broaching or hobbing...

This ends up destroying the differential to transmission mating point (when power and traction are high enough). The whole differential tries to roll forward and breaks the case, and trans output shaft. The zr1 vettes have significantly stronger differential cases as a result, at least for the...

Thank you for the resources WKTaylor The spline is just to fit the hub that is in use. Roughly a 33 diametral pitch 36 tooth external on an input shaft for automotive application. It's not quite that size, but very similar to.

I see, very very valuable insight and reflection in this thread. Thank you all for your contributions.

But why? Latent heat of aluminum is so high as it is, and the conductivity is so high... why would you choose aluminum? You could likely add cooling to your part. Otherwise time to look at titanium. Aluminum isn't a hot working material.

Solid film lubricant as said, or DLC or some kind of plasma deposition. Nikasil for example... The cost should steer you away pretty quickly.

Yes there is one analysis of a nascar shaft? I believe by nasa, and they went into 300m's stress issues. Seems just so easy to end up with a surface defect that causes failure. 4340 too I think is very heat treat dependent... I really don't have the equipment to properly verify internal...

Needing to remake a splined shaft in higher strength material ("can't" resize currently... out of my hands, don't get me started). So far it seems that C300 /Vasco Max is what I'm looking for. Are there any other "latest and greatest" high yield high fatigue life, tough alloys? Or maybe...

A lot of work goes into optimizing friction materials and fluids (tribology) to manage the shift quality. Unfortunately fuel economy takes precedence over everything else. But, even though most of these 8 and 10 speeds even 6 speeds have shift quality issues, there is a lot of dedication to...

My follow up... I ended up going with pc 9020. I feel this is actually the better solution over chock fast orange. It reaches the glass transition temperature much sooner (38c vs 60c), so it will act much like what I was describing earlier. With some relief holes in place, I am not worried at...

The second pic is what's really interesting; the crack has broken the aluminum casting but not the spun cast iron, yet. Which to me is even more evidence that this is a vibrational issue.

They are all longitudinal. They all also happen intermediate of the structural support to the block deck, at the top of the sleeve. Not my pictures but this is what we are talking about. Almost all of the ones I have seen (online or in person), the crack is at the top of the sleeve, just...

Very interesting to hear about the cavitation in diesels in the coolant area. Never heard about that. I feel these vibrations in cast aluminum are what kill the block. Likely just seek out stress in the casting... As HIP is a very popular and quite a successful treatment for aluminum blocks...

Another idea I have considered is some kind of low temperature solder. The similar thermal expansion rate and conductivity to aluminum of one of these solder mixes is more appealing than epoxy. Some of the solders would be workable just above operating temp, so they shouldn't realistically hurt...

You are certainly right about the lower modulus. However, my thinking here is that if you use something that has "enough" modulus, but has very high damping, it would do the job "better" by reducing stress build up from differential thermal expansions. Nothing will expand quite like aluminum...

Those are both really interesting, thank you for the recommendations. Chockfast Orange has quite a nice thermal expansion rate, and other really nice ratings... I wish I had more blocks to experiment on. I'm surprised I haven't heard of this before. Thanks again

I have been very interested in block fillers, specifically block fillers for aluminum engine blocks. Originally these were used in iron blocks, and were aggregates similar to precision grouts (Embecco 885 or Masterflow 885). More recently things like Loctite PC 9020 have been used with some...

Keep in mind that different teams and drivers have different settings, for different stages/conditions. I will remind you that the car is driven mostly with weight transfer to facilitate rotation of the chassis. Rather than active steering input. How or why a rear disconnect is implemented is...