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From: "George Lendich" <lendich@aanet.com.au>
To: "Rotary motors in aircraft" <flyrotary@lancaironline.net>
References: <list-4493767@logan.com>
Subject: Re: [FlyRotary] Re: Permanent Magnet Alternators
Date: Wed, 6 Oct 2010 08:37:50 +1000
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Ernest,
Although I must agree with Ed, I also understand your approach.
Mt very first job was in a Foundry, pouring molten metal by hand with an old 
chap on the other handle end of the crucible. Since then I've done a lot of 
things but I'm glad I moved on from that.

Aluminium casting is, as much a dark art as much as it is science. Large 
thin parts are difficult without pressure injection casting- which is high 
cost

 Hand casting can leave unseen voids and evenly distributed bubbles in 
overheated metal - which all lead to low strength parts.

The beauty of commercial plate is the consistency in strength, without 
porosity. That's why Tracy used plate instead of a cast bellhousing. There 
wouldn't be enough demand to set-up for a pressure injection unit which is 
the compromise between strength , cost and weight.
For motor mounts I would use chrome molley.
George (down under)

>I was getting worry, Ernest about the "level" to which you were descending 
>to produce components - I figured next you would start building an electric 
>ore furnance to smart smelting your own aluminum for you casting efforts 
>{:>)
>
> Personally I think you are better off machining it out of know quality 
> plate aluminum - as you have undoubted found out consistency can be 
> difficult to achieve with large castings of aluminum - and therefore 
> strength and hidden flaws can be of concern - particularly when used as a 
> motor mount.
>
> We all want you to stop goofing off and fire up that engine - its been - 
> what three years or more since I flew up and blessed your engine assembly 
> {:>) - and still no engine start?  Get busy, Ernest and stopped getting 
> diverted by undoubtedly interesting - but time consuming side projects. 
> There's way too many projects and  only so much time (and money) to build 
> and airplane{:>)
>
> Ed
>
> Edward L. Anderson
> Anderson Electronic Enterprises LLC
> 305 Reefton Road
> Weddington, NC 28104
> http://www.andersonee.com
> http://www.eicommander.com
>
>
> --------------------------------------------------
> From: "Ernest Christley" <echristley@att.net>
> Sent: Tuesday, October 05, 2010 9:51 AM
> To: "Rotary motors in aircraft" <flyrotary@lancaironline.net>
> Subject: [FlyRotary] Re: Permanent Magnet Alternators
>
>> Kelly Troyer wrote:
>>> Todd and Ernest,
>>>  Anything to report on your Permanent Magnet Alternator installations 
>>> ??...............
>>>
>>
>> I spent last Saturday trying to cast an aluminum mount for my rotor.  I'm 
>> really not happy with the sheet metal mount I built.  I've been 
>> practicing casting, and I've made several parts, including a couple of 
>> crank angle sensor mounts (1/4" of aluminum makes for a really stiff 
>> mount).
>>
>> It turns out that the difficulty of metal casting is proportional to the 
>> cube of the parts size.  Right now, I have a chunk of aluminum the size 
>> of a one-gallon paint can stuck in my furnace.  I ran out of fuel just as 
>> the last ingot was starting to melt, and after that disaster I discovered 
>> a small hole had formed in my crucible and was slowly filling the bottom 
>> of the furnace.
>>
>> That's when I decided that I would just order a 12"x12"x2" 6061-T3 
>> aluminum plate and machine it.  I started down the path of a casting 
>> before I bought my 12" lathe, but the machining makes more sense anyway.
>>
>> This is the last major part I need before moving on to an engine start, 
>> so the delay kinda sucks, but at least I have a new skill.  I'm going to 
>> apply it to making tap handles for the kegs that we use at work during 
>> our Friday Beer Bash.
>>
>> --
>> Homepage:  http://www.flyrotary.com/
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>>
>
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