I have recently been asked to manufacture 1 off replacement Ducati wheel speed sensor bracket.
The original one was manufactured as 2 separate pieces and then welded together. This had been knocked and bent.
I managed to straighten this out, nick through the existing weld and re-weld around 3 sides to”repair” the original.
Knowing that this original design may have a weakness where the joint between the 2 parts are only able to be welded on 3 sides, I machined the item as a single part, using a manual lathe and mill.
The material I used was HE30 Aluminium, or what is now commonly known as “6082 grade alloy” or “T6″.
Particulars of this grade of material is ideal for this application – “Alloy 6082 is a medium strength alloy with excellent corrosion resistance. Alloy 6082 has the highest strength of the 6000 series alloy. Due to the higher strength of Alloy 6082 it has replaced Alloy 6061 in many applications. Alloy 6082 is typically used in highly stressed applications, Trusses, Bridges, Cranes, Transport applications, Ore Skips, Beer Barrels, Milk churns”. (taken from http://www.aircraftmaterials.com/data/aluminium/6082.html 30/9/2013).
A more typical application for this grade is aircraft parts, billet alloy slab yokes, fork clamps, handlebar risers.
Above image shows 1 piece sensor bracket, machined from billet T6 Alloy, etch primed and painted silver
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