Flow-formed differential case assembly

1. A differential case assembly, comprising:

a gear assembly;

a differential case having an open end and a side wall with an exterior surface, the open end having an opening configured to receive the gear assembly therethrough, at least a portion of the exterior surface of the side wall forming an outwardly extending lip adjacent the opening, the exterior surface of the side wall having a base spaced apart from the lip;

an integral end cap and ring gear assembly disposed over the open end of the differential case and adjacent the exterior surface, the integral end cap and ring gear assembly covering a portion of the opening at the open end of the differential case and cooperating with the differential case to house the gear assembly, a first interior portion of the integral end cap and ring gear assembly abutting the exterior surface of the differential case to define a weld joint interface between the lip and the base, a second interior portion of the integral end cap and ring gear assembly spaced apart from the exterior surface and defining a void therebetween, the void permitting a first welding operation of the differential case to the integral end cap and ring gear assembly at the weld joint interface adjacent the base, wherein a diameter of the weld joint interface decreases from the base towards the lip, the integral end cap and ring gear assembly has a plurality of slots formed therethrough, each slot exposing a respective portion of the lip and the weld joint interface adjacent the lip, each slot permitting access to both the differential case and the integral end cap and ring gear assembly for a second welding operation of the differential case to the integral end cap and ring gear assembly at the weld joint interface adjacent the lip;

a first weld formed by the first welding operation at the weld joint interface adjacent the base;

a plurality of intermittent second welds formed by the second welding operation at the weld joint interface adjacent the respective portion of the lip exposed by each slot; and

a minor void disposed at the weld joint interface between the exterior surface of the side wall of the differential case and the first interior portion of the integral end cap and ring gear assembly, minor void permitting a collection of gases during at least one of the first welding operation and the second welding operation.

2. The differential case assembly of claim 1 , wherein the weld joint interface is disposed on a plane oriented at an acute angle relative to a central axis of the differential case.

3. The differential case assembly of claim 2 , wherein the angle is up to about 15 degrees.

4. The differential case assembly of claim 2 , wherein the base is disposed on a plane oriented orthogonal to the plane on which the weld joint interface is disposed.

5. The differential case assembly of claim 1 , wherein a ledge is formed in the integral end cap and ring gear assembly, the ledge exposing the weld joint interface beneath each of the slots.

6. The differential case assembly of claim 1 , wherein at least a portion of the integral end cap and ring gear assembly extends radially inwards beyond the exterior surface of the side wall of the differential case at the open end thereof.

7. The differential case assembly of claim 6 , wherein the at least a portion of the integral end cap and ring gear assembly abuts a surface defining the open end of the differential case.

8. A differential case assembly, comprising:

a gear assembly;

a differential case having an open end and a side wall with an exterior surface, the open end having an opening configured to receive the gear assembly therethrough, at least a portion of the exterior surface of the side wall forming an outwardly extending lip adjacent the opening, the exterior surface of the side wall having a base spaced apart from the lip;

an integral end cap and ring gear assembly disposed over the open end of the differential case and adjacent the exterior surface, the integral end cap and ring gear assembly covering a portion of the opening at the open end of the differential case and cooperating with the differential case to house the gear assembly, a first interior portion of the integral end cap and ring gear assembly abutting the exterior surface of the differential case to define a weld joint interface between the lip and the base, the integral end cap and ring gear assembly having a plurality of slots formed therethrough, each slot exposing a respective portion of the lip and the weld joint interface adjacent the lip, each slot permitting access to both the differential case and the integral end cap and ring gear assembly for a welding operation of the differential case to the integral end cap and ring gear assembly at the weld joint interface adjacent the lip;

a plurality of intermittent welds formed by the welding operation at the weld joint interface adjacent the respective portion of the lip exposed by each slot; and

a minor void disposed at the weld joint interface between the exterior surface of the side wall of the differential case and the first interior portion of the integral end cap and ring gear assembly, the minor void permitting a collection of gases during the welding operation;

wherein a diameter of the weld joint interface decreases from the base towards the lip.

9. The differential case assembly of claim 8 , wherein a ledge is formed in the integral end cap and ring gear assembly, the ledge exposing the weld joint interface beneath each of the slots.

10. The differential case assembly of claim 8 , wherein a second interior portion of the integral end cap and ring gear assembly is spaced apart from the exterior surface and defines a void therebetween.

11. The differential case assembly of claim 10 , wherein the void permits the welding operation of the differential case to the integral end cap and ring gear assembly at the weld joint interface.

12. The differential case assembly of claim 11 , wherein the weld joint interface is disposed on a plane oriented at an acute angle relative to a central axis of the differential case.

13. The differential case assembly of claim 12 , wherein the angle is up to about 15 degrees.

14. The differential case assembly of claim 12 , wherein the base is disposed on a plane oriented orthogonal to the plane on which the weld joint interface is disposed.

15. A method for manufacturing a differential case assembly, the method comprising the steps of:

providing a differential case having an open end and a side wall with an exterior surface, the open end having an opening configured to receive a gear assembly therethrough, at least a portion of the exterior surface of the side wall forming an outwardly extending lip adjacent the opening, the exterior surface of the side wall having a base spaced apart from the lip;

disposing the gear assembly within the differential case through the opening in the open end;

disposing an integral end cap and ring gear assembly over the open end of the differential case and adjacent the exterior surface, the integral end cap and ring gear assembly covering a portion of the opening at the open end of the differential case and cooperating with the differential case to house the gear assembly, a first interior portion of the integral end cap and ring gear assembly abutting the exterior surface of the differential case to define a weld joint interface between the lip and the base, wherein a diameter of the weld joint interface decreases from the base towards the lip, the integral end cap and ring gear assembly having a plurality of slots formed therethrough, each slot exposing a respective portion of the lip and the weld joint interface adjacent the lip, each slot permitting access to both the differential case and the integral end cap and ring gear assembly for welding of the differential case to the integral end cap and ring gear assembly at the weld joint interface adjacent the lip; and

welding the differential case with the integral end cap and ring gear assembly at the weld joint interface adjacent the lip to form a plurality of intermittent welds at the weld joint interface adjacent the respective portion of the lip exposed by each slot, wherein a minor void is disposed at the weld joint interface between the exterior surface of the side wall of the differential case and the first interior portion of the integral end cap and ring gear assembly, the minor void permitting a collection of gases during the welding.

16. The method of claim 15 , wherein the welding includes a laser welding operation.