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Current gearbox technology utilizes metallic gears due to the high strength and thermal capabilities. While metal is an excellent choice for these conditions, it is also heavy and prone to corrosion. Gear rotation and the resulting meshing of gear teeth generate vibration that results in noise. For these reasons, a hybrid metal-composite design was identified to provide weight and noise reduction benefits, due to the reduced density and improved damping of composite materials.
A single hybrid gear has now been tested without failure for 400 million cycles in representative gearbox conditions, including rotational speed, torque and hot oil. The weight of the gear, even though o