Questions tagged [aluminum]

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What kind of stress can forged aluminum take?

I have a motorcycle frame. It is made form forged aluminum. There is a pressed headset in the frame that I need to remove - it was pressed in there with machined force. Some folks remove the headset (...
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3 answers
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Is it possible to tap a hole partially through a 3mm aluminium sheet?

I would like to secure components to an aluminium sheet that is 3mm thick. Ideally I do not want to drill holes all the way through the sheet because it is important that a seal is maintained. I am ...
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Is a block designed for water cooling effective at dry transmission of heat?

I’m working on a project involving a thermoelectric cooler, and options for small aluminum or copper blocks have been few and far between. However, I found many cheap aluminum and copper blocks on ...
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2 answers
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Resources for strength calculation for an outside aluminium loft ladder and what about it becoming brittle in cold weather?

I have been thinking for years about building an outside stair / loft ladder to climb from a platform to another one, one stair higher (3 meters). However, I never studied material strength, and I don'...
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What aluminum grade is the most resistant to corrosion in alkaline environment?

Quick google search will return either 6000 series (6061 more specifically), or 3003 However with so many option and each having it's own benefit, I still haven't make my decision What I am looking ...
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Aluminium Bolt in Titanium Casing: Any Dangers of (Contact-)Corrosion?

Assumed we have a fuel flask that is made of titanium. The bottle will be filled with white gasoline when used. At the bottleneck there is a standardized thread manufactured into the titanium. Are ...
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Is it possible to estimate the young's modulus of an aluminum alloy purely based off its alloy designation?

I recently had an interview where the interviewer asked what the young's modulus would be like for an alloy like 5052 versus 6061. was a bit stumped on this one, saying that 5052 might be lower ...
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Is welding aluminum a good choice?

I am making an aluminum part with a sort of a built in pipeline where water runs to cool the system. To close and seal the "pipe" I would need a lot (at least 144!)screws and two very long (...
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Can a lunchbox made from neoprene be as effective as one made from foam and aluminum foil at keeping its contents hot or cold over time?

Aluminum foil reflects radiant heat while neoprene doesn't. On the other hand, aluminum is highly conductive while neoprene is an insulator. So there must be differences in the way these two materials ...
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2 answers
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What thickness aluminum plate will support 350lbs?

I need to purchase an aluminum plate that is 19.625" x 24", that can support 350lbs. This will hold pavers + possibly a person, next to a pool on top of an automatic cover. The automatic ...
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2 answers
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Reliable non-welding ways to attach square aluminium tubes to aluminium frame?

Question. What non-welding options do I have to reliably attach square aluminium tubes to an aluminium frame? Context. This will be used for outdoor environment (gate). I'm thinking of non-welding ...
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6 answers
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Can aluminium foil be a thermal insulator?

I've searched on Google that aluminium foil can be a thermal insulator, but how does it work? From my thought process, it should've been a conductor because its a metal, right? But, some said that ...
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9 answers
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Aluminum weight saving

"Aluminum saves weight! Its 3 times lighter than steel!" Also its 3 times weaker and 3 times softer. When comparing stiffness and strenght to weight ratio, aluminum isnt any better than ...
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1 answer
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Computing the required thickness of an aluminum sheet to support a given load

I want to fabricate an aluminum shelf for my media center. 22 1/16” x 37 5/8” with a rectangular cutout 2 1/2” deep on one of the long edges of the sheet with 6” of material on either side of the ...
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What is the difference between wrought aluminum and cast aluminum? Is it possible to cast 6061 aluminum?

I'm currently learning about material properties and I'm not certain what the main differences are between the different types of aluminum. The aluminum I'm most familiar with is 6061-T6 aluminum and ...
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2 answers
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Software for designing products made of aluminum extrusions

I'm going to build a storage cabinet out of aluminum extrusions. Something that looks like that, except lighter and less intricate: So yeah, my cabinet will be a lot lighter and without moving parts. ...
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2 answers
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How to achieve textured matte paint finish on flat aluminium

I have aluminium gates, made of sheets. If I paint it using normal powder coating, it looks shiny and reveals imperfections (e.g. mild bends) depending on the angle at which sun light hits it. I am ...
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2 answers
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Feasibility of reconstituting existing 5083 Aluminium

Can I melt 5083 aluminium and then reconstitution into a mould. I would like to know if it is possible to melt down existing 5083 aluminium lp and then pour the molten liquid into a yacht mould of 6mm ...
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How much deflection can/should I accept with Aluminum Extrusions?

I plan building things with aluminum extrusions. On this website I can calculate the deflection depending on the profile length and load. https://8020.net/deflection-calculator I.e. if I select a 20/...
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Belt Drive Shaft - What Profile is This?

I'm trying to source a similar extruded aluminum round profile, that I can attach a belt to, as in the pic below. The shaft will turn and pull on that belt. I looked at the 80-20 extrusions and ...
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Would 6061 or 5052 Aluminum have lower rate of creep?

I am making a device which uses a bent thin sheet of aluminum as a spring which provides a constant force. It must be made of aluminum. Over time the material will relax and the force of the spring ...
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How to determine minimum aluminum t-slot profile type for frame?

For a frame with dimensions 1000x1000x400, I am determining which T-slot extrusion type will be strong enough. I am considering both 30-6060 (30 series I-type, metric) and 20-4040 (20 series I-type, ...
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Maximum strength size thread for aluminium sheet per thickness

Is there a rule of thumb, or a table which helps one determine what is the maximum strength thread size to use for aluminium sheet? I am interested in threading 3mm, and 2mm thick sheet aluminium. I ...
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1 answer
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Mounting methods for thin wall cast aluminum

Having a cast aluminium enclosure with the 3mm wall thickness. now I need to mount this to a mounting plate which fixed in vertical walls. can I have some idea on how should I choose the appropriate ...
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1 vote
1 answer
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What thickness do I need for a 30x30 (cm) aluminium plate to hold 350Kg on three points?

I want to make a strong connected weight-scale Arduino project, for which I already own 3×350Kg sensors (red). I plan to make the plate (green) around 30cm×30cm in 99.5 Brut aluminum, with my three ...
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3 votes
3 answers
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Shade tree engineer needs help calculating hoop stress

I have an extruded aluminum tube. I'm trying to come up with an Excel calculator that will help me find out how much force would be exerted on the internal walls if the tube was filled with rubber, ...
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1 vote
4 answers
1k views

Aluminum square tubing capacity question

I have an awning that I am attaching to the corner of the house. I needed to extend it so I got a piece of 6063 square aluminum tubing. It's 1 inch wide with .125 wall thickness. It has about 2 feet ...
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Should I use ST or LT values for extruded rod?

In MMPDS for AA7075-73511 (extruded rod) the Table 3.7.10.0(g3) show both ST and LT values for transverse directions. For a rod with circular cross section there is really no Short and Long transverse ...
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2 answers
404 views

What temperature required to alloy copper and aluminum?

According to this phase diagram, the melting point of 30% copper aluminum bronze is around 548°C. Lets say I create molten aluminum at 680°C, can I add small pellets of copper and swirl them around to ...
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2 votes
2 answers
89 views

Creating strongest possible sectional aluminum round tube

I want to attach a mast and sail to a dinghy. The mast length would be 10.5 feet tall to accommodate a 20-22 sq ft sail, but for transportation purpose would need to be collapsible into at least two ...
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1 vote
1 answer
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What is the purpose of the steel plate in this coupler?

I've found a shaft coupler that has a steel plate in between, but it's not clear what its function is: If it is to add strength to the coupler, isn't the coupler as strong as the weakest link, i.e. ...
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3 votes
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Is having a keyway in aluminium for 30Nm a bad idea?

I'm designing an aluminium shaft hub for a 16mm keyed shaft with a maximum torque of 30Nm. However, stress analysis tells me that the keyway can suffer too much stress: If my understanding is correct,...
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2 votes
1 answer
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Why are aluminum tubes folded at the end

I've noticed that aluminum squeeze tubes have a fold at the end. The fold is not the seal of the tube, as I can unfold and see the seal on the very end of the tube once unfolded. Wikipedia states that ...
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1 vote
0 answers
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How to repair stripped, leaky pneumatic fitting?

I have a pneumatic cylinder with a stripped fitting, which causes a slow leak. I took it to a machine shop and he tried to re-thread it but there wasn't enough good metal left to get a good thread. He ...
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1 vote
2 answers
686 views

Calculating tensile strength for aluminium

I'm making a Z (coffee table) linkage with two interlocking C channels and a couple of steel linkage bars. While moving, they aren't load bearing but when extended, they will take a weight of around ...
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2 votes
2 answers
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How can I square off a piece of aluminum bar after cutting without a milling machine?

When I cut aluminum bar or t-slot extrusion on my bandsaw I am not happy with how "square" this edge is. I don't have a milling machine at home, and I have been told grinding aluminum is a very bad ...
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0 votes
1 answer
213 views

How to properly fit almuminum glass window without leakage?

I got a brick-wall house. The wall is 25cm thick. I want to add windows. There are 2 ways of adding a window: Adding the window on the inside side of the wall, so that if the aluminium frame of ...
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1 vote
0 answers
98 views

How do I to connect aluminium profiles with 60 and 120 degree angles?

I would like to construct an aluminium profile frame which includes connections with stiff fixed angles at 60 and 120 degrees. What options do exist for creating those connections, preferably without ...
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1 vote
1 answer
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Is there any way to improve the strength of simple at-home aluminum/copper/brass castings (sand-casting hammers)

I'm just getting-into melting-down cans to make aluminum-based slingshots, hammers and the like. In my ignorance I didn't realize that copper/brass were also things that I could process which has ...
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1 vote
1 answer
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Mounting outdoors camera using aluminum 5052

I designed a simple U shape 2mm sheet metal bent mount for a 4kg outdoors CCTV camera. The mount was accidentally produced from 5052-H32 Aluminum instead of 6061-T6. Is it common to use 5052 ...
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2 votes
2 answers
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What is the manufacturing method used to make aluminium C channel

I don't know how this is made and I don't know the name of the method to search for it to learn more.
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0 answers
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How to produce aluminium powder by E. J. Hall method

I have watched videos on YouTube producing Aluminum powder by mechanical methods. Like this one. It uses Aluminum foil and coffee grinder: There are similar videos which use the same basic method but ...
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1 vote
0 answers
188 views

Building bed out of 8020 aluminium extrusion

I want to build a rock and roll bed out of 8020 aluminium extrusion, in order to avoid the bother of welding steel pipe. However, I don't have much of a 'feel' for how strong this stuff is. Will ...
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0 votes
4 answers
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small relatively inexpensive crack detection apparatus for bike shops

Is there a relatively inexpensive (let's say under $500US) crack-detection device and related mobile app that would be easy enough for a non-engineer/non-metallurgist to use to determine whether a ...
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1 vote
1 answer
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Tapped thread maximum load

I am building a stair from aluminium to go to my basement, the stair sides-plates are made from 10mm thick aluminium AWS 5454. I am planning to tap M10 thread into this plate. To avoid the step ...
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1 vote
3 answers
491 views

How can I calculate "bendability" of aluminium tubes?

Disclaimer: sadly not an engineer (I hope this is the right place for such my question. Please let me know if it isn't). I'm designing a tent. I know most of the dimensions of the first prototype I ...
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1 vote
1 answer
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Small scale aluminium tubes manufacturing

Our startup needs short aluminuim tubes (max. ~70 cm [~27.5 inches] long / less than 1 cm / 0.4 inch diameter) such as these: We'd prefer to manufacture them ourselves rather than buy them from a s ...
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1 vote
1 answer
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Is it possible to replicate a motorcycle engine cylinder head?

Is it possible to create a mold of an aluminium motorcycle cylinder head so that you can create an exact replica with melted aluminium?
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1 vote
4 answers
480 views

deformation / bending problem with anodized aluminium panels

I recently had a machine shop machine some aluminium panels (3mm thickness) which I then sent to an anodizing shop where the panels were bead blasted and anodized. When they came back they were ...
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4 answers
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Benefits and disadvantages of aluminium alloys as a replacement for structural steels in ships

My Answer. Benefits: The major advantage of aluminum in ship building is its strength to density ratio. Aluminum has high tensile strength with less weight, which results in lowering the weight of ...
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