Aluminum sprockets for drive train - several questions

[AdamHeard]

I've worked on several drivetrains based on AndyMark's plate sprockets (both #25 and #35). So far have never had an issue with wear or failure. If you run the numbers, the size of the sprockets in a usual dead axle drive and the usual torques in such a drive show they are plenty fine; and if they aren't, just bump up to a larger sprocket until they are. I love them so much that all dead axle drives I work with are designed to specifically interface with the plate sprockets stock.

We've only had one issue, and that was a set of #25 with slightly misshaped teeth (Andy said because of feedrates). We mentioned it, and they were very promptly replaced.

[Triple B]

233 has used #25 chain on our drive wheels for 10 years with no wear problems. They were manufactured from 6061 aluminum with no anodizing. Our robot from 2003 still runs and has the original sprockets. Before we went to direct drive we used steel sprockets on the output shaft for strength of the shaft/sprocket interface.
mike d