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I Steel Haven't Found What I'm Looking For.

2/28/2015

12 Comments

 
Why do I make so many tools from Aluminum alloy, instead of steel? Surely it would be better to make it for the long term? Well its a bit of a sore point, but I'm glad you asked!

In my part of the world (a far flung corner of Australia) good quality steel is virtually unheard of. There is an abundance of that gummy hot rolled stuff. Local industry use it, and there are plenty of off-cuts if desired, but they want a pretty penny for scraps. And it's just awful to work with.

Ask for cold rolled steel, and you can expect a good natured shrug. Ask for anything more exotic like 12L14, or the wonderful (UK) EN8M, and there will definitely be furrowed brows. It just doesn't get used by our local manufacturers, so they never see it.  Gauge plate is unobtainium, although drill rod is still available from Blackwoods.

Basically we just don't have a steel industry in our country that even remotely equates to the UK or US. If we need the good stuff, we model engineer types have to really pay through the nose, by ordering  from specialist suppliers, mostly overseas/online.

Aluminum alloy on the other hand, is as common in my part of the world as water. All dimensions, grades, you name it. And I have a couple of local fabricators nearby that use a lot of it, so off-cuts are thick on the ground. (off topic - is there any better way to spend an afternoon, than by browsing the local off-cut rack, scoring some really choice cuts of aluminum for the next project? I think not!)

So when it comes to a substantial tool, my first thought is: "Can I get away with aluminum or maybe even brass?". Because I know steel is going to really hurt the wallet.

Usually its a question of wear and rigidity. For extra rigidity, I usually increase any critical dimension to account for the increased flex. For example, I think it was borderline making my Vise Sub Table from aluminum. But I stiffened it up by adding a bracing section underneath, and it sits like a rock in the vise. I don't have a need to push it too hard, and thus far it has served really well.

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Vise Sub Table
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Reinforced with a brace
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The brace is also gripped by the vise
Regarding wear, the Aluminum certainly bruises very easily, and if it is part of an assembly that has relative movement, it also wears rapidly. But most of the tools I am making will have low cycles, so it's usually not an issue. I treat the critical stuff (mating surfaces, threads etc) with kid gloves, and thank my lucky stars that I didn't have to fork out a fortune for the steel.

If the worst happens, and it becomes clear that the aluminum is not up to the task long term, well at least I have a finished prototype that has been in the field for a while, to use as the living blue-print for re-making it in steel.

The other bonus from Aluminium of course is that its an absolute pleasure to machine; No excuses for a poor surface finish!

Thanks for stopping by,
Chris.
12 Comments
Andy
4/10/2015 12:59:43 am

G'day Chris, if you're still after engineering steel, have a look at a local company, Interlloy (http://www.interlloy.com.au/). They're a little pricey, and have a $100 minimum, but there's not much that you can't get from them - literally every grade of steel imaginable, as well as bronze, brass, iron and aluminium.

Reply
Chris link
4/10/2015 05:17:03 am

Thanks Andy, I'll check them out.

Reply
Bob link
4/15/2015 09:47:11 pm

Hello Chris,

I'm extremely impressed with your efforts!....The vids are excellent and really sharp and clear. I have recently been playing about with my own vids but have so far been defeated by the file criterias and types. I am the workshop manager (and member) of Epping Forest Horology Club in the UK and would really like to add quality vids to our website, not to mention YouTube since we are always keen to get new members. Your superb vids have made up my mind to redouble my efforts!

The topic on your blog about difficulties with aquiring materials made my mate and I smile,...to buy the materials for your current clock,..the large wheel skeleton, in the UK is about £400 and even then not easy to source unless one goes to Ian Cobb. The clock I am just completing is about 80% made from choice scrap including the frame screws made from supermarket trolley!! The new clocks I am about to start on will be virtually all made from scrap....I'm currently mixing up casting sand to cast teh frames from plumbers scrap,..and, of course, some supermarket trolley will be used as well!

In addition to this, all of my engraving tools were made from old files and I have found that old kango hammer bits are always good stock to make tools from after annealing,...also many car parts and bearings etc

....Anyway Chris, keep up the good work we are watching with much interest!....Kind Regards, Bob

Reply
Chris link
4/16/2015 01:26:16 am

Hi Bob,

Lovely to hear from you! I have just been through your website; what an impressive workshop! Your members are very fortunate to have this excellent facility to learn and share in. I so wish there was something like this in my area.

Yes the cost of materials doesn't really help attract new members does it? I like the sound of the scrap clock though, especially the shopping trolley components - can't wait to see that one! I would love to see how you do your brass casting too. That's something I really want to try.

Glad you're enjoying the video's, and thank's for getting in touch.

Cheers,
Chris.

Reply
Christian
5/5/2015 02:33:33 pm

Hello Chris,

Really great website and videos. My son and I have enjoyed watching the videos together. One place that's good for getting O1, brass etc, rod, flat, plate in a variety of length and sizes is Amazon. Sometimes you have to play with lengths to get international shipping i.e. they don't ship 1' but 3' is OK???

I've got plenty of stock from them much cheaper (including postage) than I can get in Melbourne.

Regards, Christian

Reply
Chris link
5/5/2015 09:10:55 pm

Thanks for the tip Christian, I didn't know that - I'll check it out. I need some 1" x 1/2" O1 rod stock for a new project, so you've mentioned this at the perfect time!

Cheers,
Chris.

Reply
Mark link
8/26/2015 09:56:15 am

Hello Chris,

Great website and videos. I love the attention to detail.

One vendor I've found to be very useful for sourcing metal in Australia is offcuts galore. The products are offered on an ebay store called offcuts.galore.

George, who runs this store will list the type of metal he is offering, as much as he knows, and in the past he has sourced particular grades and sizes of steel, aluminium and delrin for me. You mention 12L14 free machining steel and I have bought this from here in the past. He also sells engineering plastics.

I am not affiliated with this company, just a customer. Hope this helps for you as a new source of raw materials.

Regards,
Mark

Reply
Chris link
8/26/2015 11:00:52 am

Awesome Mark, thank you very much! I will go check him out now.

Cheers,
Chris.

Reply
Claire link
8/27/2016 09:16:26 pm

Steel hurts the wallet even in my country;) But sometimes you don't have a choice. Good job!

Reply
Sarah Smith link
3/23/2019 05:24:48 am

It's really interesting that there are so many different ways to fabricate metal. I thought that it would be easier to find a quality steel fabrication company. Maybe I could find a local steel fabrication company.

Reply
Amy Winters link
5/23/2019 09:24:35 am

As I was reading your article on metal fabrication, you state that in your neck of the woods, aluminum alloy is a standard metal where you live. I had no idea that it can be harder to get different types of metals in other parts of the world. Thank you for writing such a great article on the kinds of industrial and manufacturing metal you have access to be able to create your tools.

Reply
Sarah Smith link
6/8/2019 04:29:07 am

It's interesting that the UK and US have larger steel industries than our own country. In my mind, that means that more people should source their building materials locally. Since my husband and I would like to get a strong fence installed on our property, we will start looking for a steel fabrication service near us.

Reply



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