Flanged tubular axle shaft assembly

A flanged axle shaft assembly comprising:

• a shaft having a tubular wall and an open end;
• a flange hub having a central opening fitted over the shaft and secured to the open end;
• and
• an end wedge secured in the open end and urging the shaft wall into compressive engagement with the flange hub opening to provide for transmission of forces between the shaft and the flange hub wherein the shaft is connected by laser welding to the flange and to the end wedge.

A flanged axle shaft assembly comprising:

• a shaft having a tubular wall and an open end;
• a flange hub having a central opening fitted over the shaft and secured to the open end;
• and
• an end wedge secured in the open end and urging the shaft wall into compressive engagement with the flange hub opening to provide for transmission of forces between the shaft and the flange hub wherein the open end of the shaft has an outwardly flared portion and the flange hub has a hub portion engaging an axially inner surface of the flared portion and wherein the end wedge has a head engaging an axially outer surface of the flared portion.

A flanged axle shaft assembly comprising:

• a shaft having a tubular wall and an open end;
• a flange hub having a central opening fitted over the shaft and secured to the open end;
• and
• an end wedge secured in the open end and urging the shaft wall into compressive engagement with the flange hub opening to provide for transmission of forces between the shaft and the flange hub wherein the shaft has an inner end axially opposite to the open end, said inner end being reduced in diameter and including external means for connecting the shaft to an axle drive assembly.

A method of making a tubular axle shaft assembly comprising the steps of:

• providing a high strength low alloy steel tubular shaft having a wall with adequate strength for use as an axle shaft;
• assembling a central opening in a preformed flange hub with a close fit on to an open outer end of the shaft;
• forcing an end wedge into the open outer end of the shaft to expand the wall of the shaft outer end into force transmitting engagement with an inner surface of said central opening to provide a force transmitting mechanical connection;
• and
• fixing the flange hub and the end wedge in position at the inner end of the tubular shaft.