Method for forming an axle shaft and related axle shaft

• US 9,895,931 B2
• Filed: 11/25/2015
• Issued: 02/20/2018
• Est. Priority Date: 03/15/2013
• Status: Active Grant

• Current Assignee: American AXLE & Manufacturing Incorporated (American AXLE & Manufacturing Holdings Incorporated)
• Original Assignee: American AXLE & Manufacturing Incorporated (American AXLE & Manufacturing Holdings Incorporated)
• Inventors: Hibbler, John C.
• Primary Examiner(s): Hlavka, David J
• Application Number:
  US14/951,555
• Publication Number:
  US 20160075179A1
• Time in Patent Office: 818 Days
• CPC Class Codes: B23K 20/12 the heat being generated by friction; Friction welding
• CPC Class Codes: B60B 2310/302 by welding
• CPC Class Codes: B60B 2360/102 Steel
• CPC Class Codes: B60B 2380/70 Arrangements
• CPC Class Codes: B60B 2380/90 Casings or housings specially adapted to receive bearings
• CPC Class Codes: B60B 35/125 of the planetary type
• CPC Class Codes: B60B 35/16 Axle housings
• CPC Class Codes: B60B 35/18 Arrangement of bearings
• CPC Class Codes: F16H 2048/082 characterised by the arrangement of output shafts
• CPC Class Codes: F16H 2048/087 characterised by the pinion gears, e.g. their type or arrangement
• CPC Class Codes: F16H 2048/426 characterised by spigot bearing arrangement, e.g. bearing for supporting the free end of the drive shaft pinion
• CPC Class Codes: F16H 48/08 comprising bevel gears
• CPC Class Codes: F16H 57/037 Gearboxes for accommodating differential gearings rotating cases for differential gearings F16H48/40

Abstract

A method for forming an axle shaft that includes friction welding a tubular shaft to a shaft portion of a wheel flange. Portions of the joint members on the tubular shaft and the wheel flange are extruded into an annular weld cavity in the wheel flange during the formation of the friction weld. A related axle shaft is also provided.

Claims

1. A method for forming an axle shaft, the method comprising:

providing a wheel flange having a rotational axis, the wheel flange defining a shaft portion, a first joint member and a containment lip, the first joint member having an annular shape and extending along the rotational axis concentric with the shaft portion such that an annular weld cavity is formed radially between the first joint member and the shaft portion, the containment lip being fixedly coupled to the shaft portion and extending radially outwardly therefrom, the containment lip bounding a distal end of the annular weld cavity;

providing a tubular shaft that defines a second joint member; and

causing relative rotation between the wheel flange and the tubular shaft while engaging the first and second joint members to one another to thereby form a friction weld that retains the wheel flange to the tubular shaft;

wherein portions of the first and second joint members are extruded during the formation of the friction weld, the extruded portions of the first and second joint members being received into the annular weld cavity radially inward of the containment lip.

2. The method of claim 1, wherein the tubular shaft is formed of a steel material having a carbon content that is less than or equal to 0.35% by weight.

3. The method of claim 2, wherein the tubular shaft has a surface hardness that is greater than or equal to 45 Rockwell C.

4. The method of claim 2, wherein the steel material is a moderate strength low-alloy or plain carbon steel material.

5. An axle shaft comprising:

a wheel flange having a rotational axis, the wheel flange defining a shaft portion, a first joint member and a containment lip, the first joint member having an annular shape and extending along the rotational axis concentric with the shaft portion such that an annular weld cavity is formed radially between the first joint member and the shaft portion, the containment lip being fixedly coupled to the shaft portion and extending radially outwardly therefrom, the containment lip bounding a distal end of the annular weld cavity; and

a tubular shaft that defines a second joint member;

wherein the first and second joint members are friction welded together and wherein portions of the first and second joint members that are extruded during the formation of the friction weld are received into the annular weld cavity radially inward of the containment lip.

6. The axle shaft of claim 5, wherein the tubular shaft is formed of a steel material having a carbon content that is less than or equal to 0.35% by weight.

7. The axle shaft of claim 6, wherein the tubular shaft has a surface hardness that is greater than or equal to 45 Rockwell C.

8. The axle shaft of claim 6, wherein the steel material is a moderate strength low-alloy or plain carbon steel material.