Variable-wall light-weight axle shaft with an integral flange member and method for making the same

A method for forming a drive axle shaft, comprising:

• inserting a tubular blank in a first die including an outlet end having a die orifice;
• extruding the tubular blank through the die orifice to form an elongate tubular body with a longitudinal axis;
• selectively and locally heating a first longitudinal end portion of the tubular body;
• inserting the tubular body into a bore of a support apparatus such that the first longitudinal end portion of the tubular body projects outwardly from the bore and the body is substantially supported by the support apparatus, the support apparatus defining a second die at one end surrounding the bore;
• providing a third die comprising a mandrel configured to be received within the tubular body;
• providing a fourth die comprising a mandrel configured to be received within the tubular body;
• forming a vehicle wheel flange by moving at least one of the support apparatus and the third die toward the other of the support apparatus and the third die to sandwich the first longitudinal end portion of the tubular body between the second and third dies;
• and
• moving, prior to the forming step, at least one of the support apparatus and the fourth die toward the other of the support apparatus the fourth die to expand an inner portion of the first longitudinal end portion of the tubular body radially outwardly between the second and fourth dies;
• wherein the vehicle wheel flange includes a wheel mount configured to couple a vehicle wheel to the drive axle shaft;
• and
• wherein selectively and locally heating the first longitudinal end portion occurs prior to forming the vehicle wheel flange.