A rotor shaft assembly (101) of a type used in a turbocharger, manufactured by mounting a powder compact of a titanium aluminide rotor (203) to a powder compact of a steel shaft (207), with a metal powder admixed with a binder (211) interposed between the rotor and shaft, and debinding and sintering the mounted compact combination. Sintering produces a strong metallurgical bond between the shaft and rotor, providing a near-net rotor shaft assembly (101) and also an inexpensive and efficient method for the manufacture of an assembly capable of withstanding the high forces and temperatures within a turbocharger.