When designing a single gear or gear system, the choice of material is the main factor that determines the geometry of the gear, or the performance of the gear determines the correct material choice for the gear. There are many kinds of raw materials commonly used in gear manufacturing, and each raw material has a good choice, and its mechanical properties are ideal. The main types of materials are copper alloys, iron alloys and aluminum alloys.
Through proper alloying and processing, aluminum alloy gears can obtain various strengths. Aluminum alloy materials are usually used to produce timing belt wheels, racks and other low-stress components. The processing technology of aluminum alloy gears is the same as that of alloy steel gears (such as milling, gear hobbing, gear shaping, etc.).
Aluminum alloy can be said to be one of our most common metals. The light weight and high strength of aluminum alloy make it an ideal choice for many applications. After steel, aluminum alloys are praised for their corrosion resistance and light weight. This characteristic of aluminum makes it particularly suitable for various electrical and electronic applications, such as high-voltage hardware, gear workpieces, parabolic antennas, computer disks, etc.
What are the characteristics of aluminum alloy gears
Aluminum alloy is a better alternative to iron alloys and is suitable for applications with high strength to weight ratio. The weight of aluminum alloy is one third heavier than steel alloys of the same size. Aluminum alloy gears have the characteristics of corrosion resistance and light weight. The passivated surface can protect the aluminum alloy gears from oxidation and corrosion. This is similar to rust on steel alloys, it will cover the surface and protect it from further damage. Aluminum alloy is more expensive than carbon steel, but cheaper than stainless steel. However, they are easy to process, which offsets the increase in material costs.
Aluminum gear
Aluminum has proven to be highly versatile in history, and it continues today. The aerospace industry continues to benefit from the properties of alloys to manufacture safe, reliable and cheaper mechanical parts. Aluminum alloy material begins to deform at 400° F, so it cannot be used in high temperature environments. There are many different types of aluminum alloy materials, and the more commonly used aluminum alloy materials for processing aluminum alloy gears are 2024, 6061 and 7075.
Among these materials, 2024 aluminum alloy can be said to be a close relative of aluminum bronze, and it is also an alloy of aluminum and copper. The main alloying element in 2024 aluminum alloy is copper. When a high strength-to-weight ratio is required, 2024 aluminum can be used. However, in this case, the ratio is reversed. The copper in 2024 gives this alloy high strength, but significantly reduces its corrosion resistance. 7075 aluminum combines zinc and magnesium with aluminum to form a high-strength alloy that resists stress loads. 6061 aluminum alloy is an alloy of aluminum, silicon and magnesium. This is a medium-strength aluminum alloy with good corrosion resistance and weldability. The above three aluminum alloy gears can be heat treated to increase their hardness. Aluminum alloy gears include spur gears and helical gears.
Advantages and disadvantages of aluminum alloy gears
The aluminum alloy material in aluminum alloy gears is considered a sustainable material. A key feature is that it can be recycled while still retaining its original characteristics. This is a very big advantage, not only cost-effective, but also good for the environment. In addition, aluminum alloy gears also have the advantage of corrosion resistance. When aluminum alloy is exposed to the air, a thin layer of aluminum oxide will form on its surface. This layer protects the aluminum alloy from corrosion when exposed.
Aluminum alloy gears have higher tensile strength and lighter weight, thereby reducing the weight of the overall structure, thereby reducing fuel costs. When aluminum alloy is exposed to the air, a positive oxide layer will form on its surface, making it corrosion resistant. In addition, aluminum alloy gears also have the advantage of high strength. The strength of aluminum alloy allows it to replace heavier metals without losing the strength associated with other metals, while benefiting from its lighter weight.
Aluminum gear
The disadvantage of aluminum alloy gears is that the overall strength of aluminum alloy gears is poorer than that of steel alloy gears: although praised for its plasticity, this special characteristic of aluminum may also be a disadvantage. Compared with steel, it is easier to dent and scratch. Steel is strong and unlikely to warp, deform or bend under any weight, force or heat.
