Abstract: A propshaft assembly that includes a propshaft tube and a weld yoke. The propshaft tube has a wall member. The weld yoke has a yoke body with an annular outer surface and an annular inner surface. The propshaft tube is welded to the yoke body such that a portion of the propshaft tube is disposed radially between the annular outer and inner surfaces and embedded into an axial end of the yoke body.

Abstract: A method for forming a propshaft assembly that includes: providing a propshaft tube having a wall member that defines an inner tubular surface; providing a yoke with a yoke body and a pair of yoke arms that extend from the yoke body, the yoke body defining first and second locating portions and an adhesive groove that is disposed between the first and second locating portions; assembling the yoke to the propshaft tube such that the first locating portion engages the inner tubular surface in a slip-fit manner and the second locating portion engages the inner tubular surface in an interference-fit manner; heating the propshaft tube and the yoke; and injecting an adhesive through the propshaft tube into the adhesive groove when the propshaft tube and the yoke are at a temperature that is greater than or equal to a predetermined minimum adhesive injection temperature. A propshaft assembly is also provided.

Abstract: A propshaft assembly that includes a propshaft tube and a weld yoke. The propshaft tube has a wall member. The weld yoke has a yoke body with an annular outer surface and an annular inner surface. The propshaft tube is welded to the yoke body such that a portion of the propshaft tube is disposed radially between the annular outer and inner surfaces and embedded into an axial end of the yoke body.

Abstract: A method for forming a propshaft assembly includes: providing a tube having an annular wall member and an axial end face; providing a yoke having body and a pair of arms that extend from the body, the body defining an annular groove having sidewalls and an end face, the sidewalls being spaced apart to receive the annular wall member; spinning at least one of the tube and the yoke while engaging the axial end face to the end face of the annular groove to plasticize a portion of the yoke and a portion of the tube; and driving the yoke and the tube together to fuse the plasticized portion of the yoke and the plasticized portion of the tube together and thereby form a friction weld; wherein the tube is fused to the yoke over portions of the yoke that correspond to the sidewalls and the end face.

Abstract: A method for forming a propshaft assembly that includes: providing a propshaft tube having a wall member that defines an inner tubular surface; providing a yoke with a yoke body and a pair of yoke arms that extend from the yoke body, the yoke body defining first and second locating portions and an adhesive groove that is disposed between the first and second locating portions; assembling the yoke to the propshaft tube such that the first locating portion engages the inner tubular surface in a slip-fit manner and the second locating portion engages the inner tubular surface in an interference-fit manner; heating the propshaft tube and the yoke; and injecting an adhesive through the propshaft tube into the adhesive groove when the propshaft tube and the yoke are at a temperature that is greater than or equal to a predetermined minimum adhesive injection temperature. A propshaft assembly is also provided.

Abstract: A method for forming a propshaft assembly includes: providing a tube having an annular wall member and an axial end face; providing a yoke having body and a pair of arms that extend from the body, the body defining an annular groove having sidewalls and an end face, the sidewalls being spaced apart to receive the annular wall member; spinning at least one of the tube and the yoke while engaging the axial end face to the end face of the annular groove to plasticize a portion of the yoke and a portion of the tube; and driving the yoke and the tube together to fuse the plasticized portion of the yoke and the plasticized portion of the tube together and thereby form a friction weld; wherein the tube is fused to the yoke over portions of the yoke that correspond to the sidewalls and the end face.