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A new aluminium rig construction teqnique!

Discussion in 'DIY Motion Simulator Building Q&A / FAQ' started by Alexey, Oct 31, 2019.

  1. Alexey

    Alexey Well-Known Member

    Joined:
    Sep 23, 2014
    Messages:
    451
    Occupation:
    Electronics Technician
    Location:
    Adelaide, Australia
    Balance:
    7,854Coins
    Ratings:
    +601 / 2 / -0
    My Motion Simulator:
    3DOF, DC motor, Arduino
    20191031_130901.jpg

    There is no welding in the picture above!

    Whilst it may look like welding, it is actually aluminium brazing.
    Using a MAPP/propane gass torch (cheap and easy to get) with a medium torch nozzle.
    I was surfing facebook when one of those adds came up showing the process of aluminium brazing and I couldnt really beleive that it was true. Being only $25 I thought I'd give it a try. To my utter surprise this actually works! The solder is even stronger than the alumninum as shown in the picture below. I did a butt joint using 1.6mm aluminuim tube soldered all the way around. I then got a 1 meter long metal tube and placed it on the end of the wleded on piece. I then tried to pry off the welded join. The joint did not fail! What you can see it that the aluminuim has stretched and eventually torn. Now one could argue that the act of heating up the aluminium has weakened it and sure it probably has. I could literally jump on this weld so for making a motion sim frame, it's good enough.

    20191031_131659.jpg
    There is however one downside. Because the solder material has a high zinc content the solder will eventually corrode and so the aluminium joint MUST be painted to stop the corrosion. An unprotected solder will last just over a year in outdoor/wet environments before showing excessive corrosion. (3 year later the frame is still standing) A painted join will last much longer and being that motion sims are usually kept inside it should last for a very long time.

    Where I got my rods from:

    https://solutionwelding.com/products/rods

    I will definately be using this for my rigs construction.

    Would be interesting to see if anyone else has used these types of rods before and what kind of experience that they have had.
    • Informative Informative x 6
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    Last edited: Oct 31, 2019