Quote:
Originally Posted by Tom Line
I think you would have a hard time selling a change from aluminum to steel to many teams, not to mention quite a few air-frame firms and racecar teams.
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Funny you should mention those two industries in particular...
I learned to weld 4130 steel when I started welding for a race car team (Formula SAE) in which a vast majority of race-car frames are welded steel, the remainder are generally carbon fiber monocoque frames. In my 4 years of involvement with FSAE I never saw a race car with a welded aluminum frame. NASCAR is all welded tube steel chassis by regulation. The aluminum car chassis I have seen are not welded, like the Lotus Elise chassis is folded aluminum that is riveted and glued together. The only race vehicle that I've seen a welded aluminum chassis is a japanese sport bike, though top-end race bikes, like Ducatis, use welded steel frames.
A vast majority of small airframes and helicopter frames are welded 4130. I should know, I do welding repairs for a local helicopter shop when the mechanics need something difficult or exotic repaired. I am also in touch with a local business that plans on producing single-engine air planes, and the entire airframe is welded 4130 steel.
I completely agree with your list of aluminum benefits. Though I would add that cutting off and re-welding brackets/mounts/etc on a steel frame is not too difficult either, and I've done that PLENTY of times. One can also weld bolts (uncoated ones) directly to a steel frame, often negating the need to drill holes in the frame.