A METHOD FOR MAKING A VARIABLE-WALL LIGHT-WEIGHT AXLE SHAFT WITH AN INTEGRAL FLANGE MEMBER

A method for making a drive axle shaft (10) is provided. A tubular blank (40) is inserted in a first die (42) including an orifice (54). The tubular blank (40) is extruded through the orifice (54) to form an elongate tubular body (12) with a longitudinal axis (16). A first longitudinal end (18) of the tubular body (12) is heated. The tubular body (12) is inserted into a bore (80) in a support apparatus. The support apparatus defines a second die (84) at one end (86) surrounding the bore (80), and the first longitudinal end (18) of the tubular body (12) projects outwardly from the bore (80). A third die (100) comprises a mandrel (102) configured to be received within the tubular body (12). A wheel flange (14) is formed by moving at least one of the support apparatus and the third die (100) toward the other of the support apparatus and the third die (100) to deform the first longitudinal end (18) of the tubular body (12) between the second and third dies (84, 100).