Affordable High Strength Face Gears

"The materials properties and inability to grind highly hardened steel into face gears as well as their weight, have limited their inherent advantage and application in high power density aerospace and transportation systems. Laser fusion free-formfabrication has demonstrated custom material compositions can be net shaped produced with superior properties to the same material conventionally formed. Laser fusion fabrication is proposed to net shape produce hybrid materials combination face gearssuch as titanium webs and steel teeth with controlled nanochemistry that enhances properties over a forged and hardened steel. Material combinations will be produced in a functional graduation between the compositions and characterized for face gearapplication. A down select materials combination will be utilized to demonstrate a net shape face gear can be laser fusion produced with desired surface finish and surface tribology. The commercial applications of high performance, lightweight, low cost face gears are in a plethora of aerospace, defense, and aircraft, automotive and marine vehicle systems."