Abstract: An axle assembly includes an axle member, a flange, and a spindle. The flange is provided with a central bore. An end portion of the spindle extends through the central bore of the flange to contact an end of the axle member. A central portion of the spindle contacts a surface of the flange. Separate weld joints are formed between the axle assembly components at the two contact areas. The welding flash around the outer circumference of the weld may be removed to allow for visual inspection. A preferred method of manufacturing the assembly is by a friction or inertia welding process.

Abstract: An axle assembly includes an axle member, a flange, and a spindle. The flange is provided with a central bore. An end portion of the spindle extends through the central bore of the flange to contact an end of the axle member. A central portion of the spindle contacts a surface of the flange. Separate weld joints are formed between the axle assembly components at the two contact areas. The welding flash around the outer circumference of the weld may be removed to allow for visual inspection. A preferred method of manufacturing the assembly is by a friction or inertia welding process.

Abstract: A method and apparatus for making a formed end metal product uses a welding apparatus to perform a forging operation on the end of an elongate metal member. The metal member is located in a workholder of a welding apparatus of the type having a second opposing workholder and a mechanism, such as a hydraulic cylinder, for developing a compressive force between the workholders. The end of the elongate member is upset forged by a die mounted in one, or both, of the workholders. Following the forging operation, a formed end is located in the second workholder and welded to the end of the elongate member. A heating step can be used if hot forging is required. Preferred types of welding apparatus include friction welders, inertial welders, and flash butt welders.