Oval Alloy Tube

[Popcorn]

Does anyone have any idea of where I can get some Oval 6082 Alloy Tube 45mm x 38mm x 4mm, I search all the usual suspects without any success.

 

[Kram]

I wouldnt imagine that oval is common but another option is 42mm x4 tube and carefully squash it oval. Perhaps pushing it through a pair of adjustable rollers would do it?

How long a length do you need?

 

[Popcorn]

Only need 16inches at the most, good idea about the rollers @Kram. Got a mate with 50 ton press wonder if that would do it.

 

[hillman]

Have a google for 'Pro-formance Metals'. They can manufacture oval tube from round.
They carry some types of oval in stock, but that's very likely to be steel for things like racing car wishbones.

 

[hotponyshoes]

I'd normally 3d print formers and squash seamless tube in a vice or press.

4mm wall might be an issue (depending how big the press is?)
You could make a set of reducing formers and do it a short amount at a time

 

[Popcorn]

Cheers for that @hillman I've emailed 'em

Another good idea @hotponyshoes but unfortunately don't know anyone with a 3d printer

 

[Cheesie]

6082 is quite hard is ot not, i thinks its 6062 i get if i want to brnd or put a bead on

 

[Popcorn]

The flange and the pipe I have is 6082, think I'm gonna have a go it squashing the pipe with a bit of heat and my vice.

 

[Erie Fred]

Would this be the same as streamline tubing ?

 

[Popcorn]

Found some streamline tubing when I was searching but nothing in the right size.

 

[Kram]

I imagine you dont have a 16" long vice jaws and doing it a bit at a time may mark it.

Perhaps put it between two lengths of timber and gradually tighten clamps along the length. The timber will spread the force and give an even squish.

If you run a coarse 2" flap disk along the timbers to make a shallow groove it should help it stay in place.

 

[Popcorn]

It's actually for an inlet manifold, so only a couple of inches needs to be oval where it joins the flange. So round going oval at one end, 16 inch was just so I didn't need to buy again if I decided to change the length at a later date.

 

[RichardM]

Anneal it first.

 

[hotponyshoes]

Have you done the maths on the dimensions?

If that size can be rolled/pressed from a size of tube you can actually source in 4mm wall to get the profile you want then all good.

Another option, if you can draw the part up, is get a quote from one of the online services to have it 3d printed in aluminium

 

[Agroshield]

...doing it a bit at a time may mark it.

With a 3DP former, you could make a blend radius on the edges of the 'die' to minimise the chances of marking.

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As above, it would be good to calculate what dimensions are possible from a standard round tube and build to that rather than decide on a specific ellipse and not be able to make it. Best I can tell, a 45 x 38 ellipse has a perimeter of 130.6mm, which is equivalent to a circle of 41.6mm dia, so the 42mm tube would be a very good starting point.

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Has anyone seen LANCETHEGASS YT channel? Very skilled. It is the opposite end of the combustion cycle, but one of his films, 'exhaust fabrication - Cosworth FVC flange set' looks very similar to what the OP describes.

 

[Kram]

I wasnt aware parts could be printed in alu? Is that a laser sintering process?

 

[Agroshield]

Is that a laser sintering process?

pcbway or jlcpcb are the most well-known sites that offer this. Sniffing around there might tell you what process they use.

Attached (45 x 38 x 4 ellipse to 41.6 x 4 circle, 100mm high) is $58.85 in aluminium.

If a person went that route, it would be wise to find out if the 3DP object is weldable - spend your money, wait two weeks and the first time you wave a tungsten at it, it disintegrates back to powder.

 

[Popcorn]

Well Pro-formance Metals got back to me this morning so super fast reply, unfortunately it'd be a custom part and I'd need to order 3metres.
Got quite a bit of alloy tube so as I said earlier gonna see what I can knock up.

 

[hotponyshoes]

pcbway or jlcpcb are the most well-known sites that offer this. Sniffing around there might tell you what process they use.

Attached (45 x 38 x 4 ellipse to 41.6 x 4 circle, 100mm high) is $58.85 in aluminium.

If a person went that route, it would be wise to find out if the 3DP object is weldable - spend your money, wait two weeks and the first time you wave a tungsten at it, it disintegrates back to powder.

View attachment 479839

Most printed parts weld fine. Just clean well first. The only problems I have seen people have welding is (I think) due to the printers blasting or spraying them with something before sending them out.
Basically, prep like you would (should!) for aluminium anyway.


However, it's quite trendy for places to offer "super strong aerospace" aluminium for printing. There is not much difference in cost in the actual material grade they use although there is a high investment cost (both £ & time) so I guess they choose that for customer appeal so some grades are not particularly welder friendly.
They'll all tell you what grade they use if you ask, many will have the info on the website.
Several offer a choice of grades

 

[hotponyshoes]

I wasnt aware parts could be printed in alu? Is that a laser sintering process?

Aluminium, stainless, titanium,
Tool steel.
Gold, silver, copper, platinum,

The list goes on.

There are also new compositions of aluminium developed especially for 3d printing that offer various proformance enhancements over traditional grades.

I don't know what the limits are.
I'd guess any metal that can be welded or cast would be suitable? Providing it can be ground into a fine enough powder.

Although, even some metals that can't traditionally be welded easily (due to atmospheric reaction etc) can be 3d printed in an inert gas chamber..