Q. Best sheet metal design?

[Cothron Theiss]

Originally Posted by InFlight

There really isn't any appreciably difference in the cost of ER4043 or ER5356 filler for 5052 and 6061 respectfully.

I'll have to ask one of the machine shops I've sent parts to about why they quote 5052 welding services as cheaper than that for 6061. I'm honestly not too sure about it.

Good welding takes considerable practice however; and does not appear to be a common skill with most high school students. The over focus on performing well on standardized tests has eliminated most shop class options in the middle and high schools.

Isn't that why we're here? Quality shop classes are becoming a rarity in high schools and FRC is able to, in the right situations, fill the void and educate students.

We avoid welding aluminum if possible. We fully CAD, water-jet the aluminum sheet, bend, and rivet. You can replace a riveted assembly; you can't take apart a welded assembly. Pneumatic riveting through a series of water-jetted holes is also significantly faster than setting up for a single weld.

I think this is a matter of resources. My team does not have access to a water-jet. My team does have a mentor that's been welding aluminum for 30 years and loves nothing more than to pass on his craft. I don't know if the OP intends to weld some of the joints in his drivetrain, but I thought I'd include the information anyhow.