Abstract: A method of fabricating propellers including a number of spiral segments of a hub each having a corresponding blade portion are integrally formed by press forging. These spiral segments are then electron beam welded together to form a propeller. To ensure maximum weld strength, spiral segments are provided, which results in a longer weld seam. In one embodiment, the shaft is friction welded to the front of the propeller, a stud is welded to a rear end of the propeller, and the stud is machined to form a hydrodynamic end cap for the propeller.