Replacing Magnesium with Aluminium

[chippie51]

Hi, we're used to machining up parts in 2024 block in order to replace original magnesium and ally parts, but when casting in ally these days, again, to replace original magnesium or ally parts, what specification(s) are people using to produce parts which would, if machined, be of 2024? Just a question out of curiosity.

Hope this makes sense. Not sure it does even to me!

[sandiego89]

No idea, but if you are making a B-36 "Magnesium Overcast" flyer I salute you

[chippie51]

No idea, but if you are making a B-36 "Magnesium Overcast" flyer I salute you

Err, NO!

[wendovertom]

If I may, what application (plane) are you building for?

Tom P.

[bdk]

Hi, we're used to machining up parts in 2024 block in order to replace original magnesium and ally parts, but when casting in ally these days, again, to replace original magnesium or ally parts, what specification(s) are people using to produce parts which would, if machined, be of 2024? Just a question out of curiosity.

Hope this makes sense. Not sure it does even to me!

I am confused. A part machined from plate is generally stronger than a casting due do porosity inherent in the casting process.

2024 is generally not used for casting. 356 is a common structural aluminum casting alloy.

http://www.ewp.rpi.edu/hartford/~ernest ... _FEB05.pdf

Many of the P-51 replacement parts available today are machined from plate as a substitute for casting.

http://www.calpacificairmotive.com/products.html

[chippie51]

I am confused. A part machined from plate is generally stronger than a casting due do porosity inherent in the casting process.

2024 is generally not used for casting. 356 is a common structural aluminum casting alloy.

That's what I was getting at. We regularly have parts machined from block (2024). I was wondering what the spec was for casting where this is still required due to the design of the part. There are some parts I can think of which were originally sand cast magnesium and would be an absolute pain in the tushy to machine from ally block, so would (for limited quantity at least) still be better cast today rather than machined (although not cast in magnesium!)

[bdk]

Any foundry that does aerospace work should be able to cast 356 and it is readily available and far stronger than magnesium. Use caution when substituting heavier materials when control surface balance is involved.

3D printing of aluminum is potentially a viable alternative, but it may be hard to find someone willing to do it because it is still under development. A lot of the aerospace industry is investing heavily in the process. Maybe 5 years from now you might be able to find a place easily to build your part.

[Dave Hadfield]

I can't wait for that day!

3-D printing a cylinder head for a Bristol Pegasus -- THAT would be a pleasure...