SimBox NG

pit-build

#321

I stand corrected… You also need an electrolyte to cause the reaction…so, the sweat (salt water) from @Troll’s hands as he pulls Gs in a dogfight would provide that…actually just casual touches of the steel-aluminum joint would cause it, not to mention the sea air of @Troll’s domicile.

So yes, as you indicated, the aluminum will suffer galvanic corrosion just from being bolted to the steel. :slightly_smiling_face:

However, I found this solution on line:

So how do you avoid galvanic corrosion? You electrically insulate the aluminum from the steel. The best way to do this is to use bolts and nuts to make the joint. Use an isolating coating or paint on the aluminum and the steel to isolate them electrically. However, all of your effort will go for nothing if you just bolt the joint together. You must isolate the bolt and nut from the aluminum and steel. You do this by putting a nonconducting plastic washer between the bolt head and one side of the joint and another nonconducting washer between the nut and the other side of the joint. If the pieces being bolted are thick enough, you should also buy a nonconducting sleeve to fit on the shaft of the bolt to keep it from making contact with the steel or aluminum. Thefabricator.com.

…all things considered, he’s probably better off making an aluminum stand…or rebuilding the entire thing in steel. :sunglasses:


#322

Definately the latter. Alu is only good to about mach 2.3. Steel all the way.


#323

Grrrrreat! :weary:


#324

In aviation we use a sacrificial material, so a cheap aluminium washer or alike that will start corroding at first before anything else. Works as well. Or some really nasty protective materials that you really don’t want to touch.


#325

Oh Gods of corrosion, take from us thine humble washer in holy sacrifice so that our metallurgical sins be forgiven amen.


#326

Why does being alloys change anything?


#327

It changes the susceptibility to corrosion a lot, certain aluminium alloys hate water for example or are extremely sensitive to scratching. It pretty much determines how you handle and apply the materials in an aircraft.

Normal, unalloyed aluminium will pretty much not corrode with metal given it’s almost instantly creation of a small layer of corrosion that isolates the rest of the material. In aviation we use ALCLAD like technique’s, using 2024-T4 with a protective layer for example. ALCLAD means Aluminium Clad. In my example it’s a copper based alloy of aluminium where they waltz on a thin layer of pure Al to protect it.


#328

Well….it does but other pure metals (e.g. iron) can actually be worse on their own. The alloys have some potential for an electron “exchange” depending on the materials they have been alloyed with. True, pure iron, for example, is much more susceptible to corrosion than steel alloys (i.e. iron + carbon + chromium or nickel, etc. all the way up to stainless steel), but the alloys do have various levels of electron donor / electron acceptor.

The purpose of making alloys is that they are stronger in some way than a pure metal. The other elements set up a crystalline matrix, depending an the amount introduced, that is stronger than the original, pure metal. That said, when you start messing around making alloys, the electrochemical properties of what you make is different from the original metal and the elements added.

Technically …

An electrode at which a reduction reaction occurs is called a cathode. Reduction involves a gain in electrons, as occurs in reactions … The reduction of hydrogen ions and oxygen are thus the cathodic reactions of corrosion and the area of a corroding metal where these reactions occur is a cathode. THE ELECTROCHEMISTRY OF CORROSION

So in this case the aluminum is an anode (gives up electrons) and the steel is a cathode (takes electrons). Put them in hard contact with each other (bolt together) and add an electrolyte like humid air (especially sea air containing salt) and corrosion will start. The place it will start is likely the bolt holes where the compression of the two metals is the strongest.

A better example is baking lasagna:

In this example, the salty food (lasagna) is the electrolyte, the aluminum foil is the anode, and the steel pan is the cathode. If the aluminum foil only touches the electrolyte in small areas, the galvanic corrosion is concentrated, and corrosion can occur fairly rapidly.
Galvanic corrosion - Wikipedia

…and now I’m hungry. :slightly_smiling_face:


#329

That put it’s really nicely! Well written there Hangar!


#330

Amazing read and digest, Troll, that is one very focused simpit that needed clarity of vision from the outset, something that I lack :slight_smile: I can start off with some good ideas sometimes but they soon get muddled up, LOL.

Happy enough with my multi purpose sim set up though, but wow its nothing like yours.

What is the distance when folded out for your two Oculus sensors please?

I see you have the new Virpil throttle too, this is next on my list after the VPC T-50, wish their web site would open again soon.

That’s one amazing Simpit Troll, you must be very pleased and proud, well done.


#331

135cm (4’ 5") I could do with less, but I wanted the sensors to see a bit ‘around’ the structure.

Thanks for your praise! :blush:
It is SimBox no.2. It helped having built the old one, and tinkered with that for a few years.
Makes it easier to see what you want and need…


#332

Zinc is often used in marine applications. Would brass work as well, for washers?


#333

Not sure, doubt it though. Besides, aluminium is about as cheap as it can get, but yes it’s much like zinc in marine applications!


#334

Then it dawned on me…
The SimBox NG wasn’t finished.
Not by a long shot…!


#335

I am glad to see you purchased the cup with the lid. No spillage in the SimBox NG when going inverted / pulling negative Gs. :slightly_smiling_face:


#336

Most immpressive. But what about more “bottle-ly” beverages?


#337

I will have the engineering department work all night, on a response to your question.


#338

Getting ready for that «4G negative dive» :f14:

The ConTrollR engineering department pulled an all-nighter and came up with this solution.
We at ConTrollR would like to take this opportunity to thank you for your valuable input on the matter. We hope you will be satisfied with our efforts.

I got a stainless steel cup holder insert at the boat interior department of Biltema.
Yes, @Hangar200. Boaty stuff, in the SimBox NG!


#339

Shareholder value has just trippled!

You are awesome, Sir!


#340

I used one of these in mine. Folds up nice against the side.