aluminium chassi

[Moparigno]

Hi,
I'm evaluating to build a front subframe using rectangular aluminium extrusions. I'm wondering if anybody did a similar work and have some suggestions/feedback to share.

I'm concerned about the suspension mounts. I would use stainless steel brackets to avoid corrosion, but I need to bolt them. My idea is to weld a small piece of aliminium tube through the rectangular extrusion and use it as a guide to pass the bolt through.

Any other ideas ?

[Moparigno]

here is something similar on Audi R8 rear suspensions:

http://stadium.weblogsinc.com/autoblog/hirezpics/W8_cutaway_large02.JPG

[makoshark]

I suggest speaking to a Structural Engineer proficient in metallurgy. I'm sure there are some on here that could help with your project on here though.

[frojoe]

Two things that come to mind:

1) Just by the nature of the material, regardless if it's 6061 or 7075, the two most common/available types, aluminum WILL fail. No matter how much or how little the loading is, it will eventually fail in fatigue at some point in its life if cyclical loading is applied to it, such as road vibrations and hard corning.

2) With that much fabrication and welding, heat treating the frame will be a must to regain uniform strength in the heat affected areas of the aluminum, or else the parts of the frame not affected by weld heat zone will be stronger than the "soft" welded areas. The frame can be allowed to sit without being loaded for a certain period of time to let it age harden to regain more uniform strength, but for a high-load application like a pro-touring car, and especially with the NVH from bumps etc, the aluminum would be better off heat treated. Maybe you could pay a local powder coating place to use their oven, but might be expensive cuz heat treat can last up to 10-12 hours depending on the alloy. I believe 6061 needs much less heat treat, but I'm speaking from experience with 7005 which is a pretty rare alloy.

If neither of these scare you off.. go for it and good luck dude! But yes, definitely speak to a metallurgy/structural engineer to find out the more specific details.

[Bryce]

I love using aluminum.... take a look at my build thread.

I think aluminum has its place.

Aluminum can be stronger than mild steel, however it is more flexible. So it depends on what loads the frame will see and what deflections you are confortable with. Aluminum is 1/3 the weight and 1/3 the stiffness of mild steel. If aluminum was used to replace steel with the same exact design just thicker than it would end up weighing the same to maintain the same stiffness. however you can change the design to take advantages of the properties of aluminum.

Heat treat is a must if you plan on welding to the aluminum.

As stated before, aluminum will work harden and eventually fatigue. If your fatigue loads are 10% of your utlimate strength than you probably will get good life from the part.