How long would it take you to make this trailer hitch?

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As part of an automotive engineering competition a classmate and I designed, analysed and built a trailer hitch out of 6061 AluminumFor our team to construct this part in house it took approximately 10 hours of machining/fitting time, and 23 hours of welding time. Neither one of us had much experience tig welding aluminum, so there was a little learning curve, but our labor was cheap(free) .For you pros out there, how long would it have taken you to build this part/ what would you charge?Here is a picture of the completed trailer hitch.It was a great learning experience.
Reply:23 hours of welding time?I hope that is a misprint, as in it should be Two point Three hours, and even that would be L--O--N--G.Ten hours for "your" cuttin n fittin, I could see that.MIG welded?Pretty design but Beef Ups needed for the tow chains.
Reply:why aluminum ?
Reply:I'm not sure how long it would take to build it, less than 33 hours though.Just my thoughts, but I don't think I would trust an aluminum trailer hitch. Being new to welding aluminum I hope you don't try to use it on the road, I think it would be nice for the small off road vehicles though.Airco Ac/Dc 300 HeliwelderMillerMatic 200 (stolen)Miller Maxstar 150STLMiller AEAD200LE (welding and generating power) Hobart MIG
Reply:Originally Posted by EE51As part of an automotive engineering competition a classmate and I designed, analysed and built a trailer hitch out of 6061 AluminumFor our team to construct this part in house it took approximately 10 hours of machining/fitting time, and 23 hours of welding time. Neither one of us had much experience tig welding aluminum, so there was a little learning curve, but our labor was cheap(free) .For you pros out there, how long would it have taken you to build this part/ what would you charge?Here is a picture of the completed trailer hitch.It was a great learning experience.
Reply:With it made of aluminum, I just don't think it would hold up. The bolts would pull through those holes even if some thing else didn't break.
Reply:And surely you are not wearing those big ole heavy stick welding gloves while trying to TIG weld, are you?
Reply:Can we see any pictures of the welds closer? There are a ton of guys who can tell you exactly what you are doing wrong (Or simple areas of improvement) in seconds on here.
Reply:The trailer hitch was designed in accordance with Section 6 of Society of Automotive Engineers J684 "Trailer Couplings, Hitches, and Safety Chains-Automotive Type." Section 4.2 of this standard states that a Class II hitch must be rated to tow a trailer with gross vehicle weight rating (GVWR) of 1590 kg and support a tongue weight of 159 kg. A table summarizing our results that are derived from linear-elastic static analyses are shown below.The lack of stress concentrations about the mounting surfaces causes me to not be very concerned about the trailer hitch sheering through 1/4 plate aluminium.  If you look at the one analysis I posted above, the peak stress is 128 Mpa and the Yield Strength of 6061-T6 aluminium is 276 MPa.Last edited by EE51; 05-26-2014 at 10:13 PM.Reason: Wrong FEA Table
Reply:Yeah, We should probably get some more appropriate gloves. The sidewall on that tube was so (.375) thick that it took a lot of current/heat to even start a puddle.
Reply:I Don't think the time is crazy for a one off.I actually prefer tig welding with stick gloves.
Reply:Originally Posted by EE51The trailer hitch was designed in accordance with Section 6 of Society of Automotive Engineers J684 "Trailer Couplings, Hitches, and Safety Chains-Automotive Type." Section 4.2 of this standard states that a Class II hitch must be rated to tow a trailer with gross vehicle weight rating (GVWR) of 1590 kg and support a tongue weight of 159 kg.
Reply:This AL hitch design of yours has no relevance to practicality or suitability for FORM, FUNCTION, and USE---which 'ustah be' the guiding tenets in design for manufacture.  Just 'becuz' your FEA blesses this design--is no indication of it meeting any of the tenets in actual use. Apparently the fact that lots of localized heat annealing would occur in the weldment was ignored. Severely de-rating the entire structure's load capacity in an effort to raise its fatigue life properties (as has been done in aircraft for 85 years, rather successfully by those attuned to the 3 tenets) apparently was ignored--which it was as, you posit about your FEA    "If you look at the one analysis I posted above, the peak stress is 128 Mpa and the Yield Strength of 6061-T6 aluminium is 276 MPa."  .......ummm, allowing for localized annealing, de-rate the yield by 80%........then further for fatigue life.Ditto for ignoring the stress, wear, deformation of bolt mounting holes as Bob comments.The marked up pic below with blue lines shows:-both frame mounting legs splayed inwards, canted to horizontal and cockedat different angles (out of parallel, square and flatness to common plane)(Somewhat surprising, since it was apparently fit up on a flat Acorn platen.)-Weldment distortion, control of it, designing the parts, fixturing and processing forweld distortion control is a whole nuther topic. It can be countered to a large extent by pre-stressing.Myself and others have posted aspects concerning this on this forum. Any subsequent heat treating of any nature will induce distortion.Does an estimate for time and price mean just producing the same, whacked-outof square, flat and parallelism work that you did……or a part that is withinwhatever tolerance limits that you haven't bothered to define?Tolerancing and geometric positioning is all important to the 3 tenets--even ifyour professors blithely ignore the design details that in the end--drive and dictate cost and ultimate practicality. Any poster who throws out a estimate ignoring the distortion issues vs. unknown tolerancingis simply blowing smoke. Sure--after multiple trials, fixturing, intermediate and final destructive testing--this could see a robotic or MIG manual time for cut/fit/weld in short order…..but, for a one-off--this isn't a one-off.Blackbird
Reply:Ya, the yield strength of the material is that UNWELDED.  Weld on in and it can lose up to 4/5 of its tempered strength.  Which would put the as welded strength in the weld and HAZ and surrounding base metal at about 56MPa (i.e. in the annealed condition, the T0 condition).  56MPa for a new yield ain't too good when your max stress is 128 MPa.  And from the looks of that FEA contour plot, any areas lime green to red, that are in a welded area, you are going to have problems with.  If you dwelled too long during the welding you'll have a bigger area affected than if you didn't.  And that's assuming your welds are good.Hope you accounted for the loss of strength in your design.  Did you load test it?  Post load test PT?  Don't use that thing on the road and endanger others.
Reply:you beat me to it Dave.
Reply:I think the math behind this is pretty interesting - most guys do not have access to this type of knowledge and technology.(Including me, especially for technology)You deserve praise for thinking through the design and getting reasonable numbers based on published concepts. Personal preference, I would not use aluminum.However, from what I can see in your pics, and your statement of not have much experience, I do not have confidence that your fitting and welding skills allowed you to match the theoretical numbers in your analysis.Keep at it - an excellent start!Edit: as stated above my post - don't actually use it - it's a learning experience for a class.Last edited by MinnesotaDave; 05-26-2014 at 10:47 PM.Dave J.Beware of false knowledge; it is more dangerous than ignorance. ~George Bernard Shaw~ Syncro 350Invertec v250-sThermal Arc 161 and 300MM210DialarcTried being normal once, didn't take....I think it was a Tuesday.
Reply:Dave, pictures can be deceiving. I wouldn't say fit-up is bad based on a picture, but you are probably right. From what I can see in the pictures the welds looked to be cold (lots of etching around the weld and look to be "dripped" into the joint.) and that will certainly cause distortion.Airco Ac/Dc 300 HeliwelderMillerMatic 200 (stolen)Miller Maxstar 150STLMiller AEAD200LE (welding and generating power) Hobart MIG
Reply:I think Bob's comment about load cycling is entirely correct, if this were an application where it was going to be cyclically towing loads for 5-20 years aluminum would probably not be a suitable material. This is for an automotive engineering competition vehicle that is used in a competitions to show applications of advanced technology implementation that are intended to improve consumer acceptability, and this specific trailer hitch is made to a specific size and form factor to fit around a high voltage battery pack while exceeding the load cases required by the competition. " has no relevance to practicality or suitability for FORM, FUNCTION, and USE." You never asked the form, function or use, so I find it difficult for you to suggest that this trailer hitch is inappropriate for meeting those three tenants. As stated above, the form is to fit around specific size constraints of our vehicle while meeting competition requirements. The function and use is to reduce the weight of our vehicle by switching from a very simple mild steel support structure that was designed quickly last year to a more sophisticated aluminum hitch that reduces total vehicle weight by over 14 lbs. I definitely should have posted a better picture at a better angle, it is actually quite straight, we had about 5/16 inch difference in total width from the front to the back. The two top mounting surfaces are completely co-planar and meet flush with the carbon fiber support structure that mounts our battery pack above. There are more welds underneath the receiver tube, so that creates an illusion of terrible distortion. I wish I could show a picture of it mounted in our vehicle that shows that there are no distortion issues.After the part was welded the entire part has been sent out to be re-heat treated up to a T6 temper. Getting. There will likely need to be some mechanical straightening once that temper is achieved. The tolerances required for this to be functional in our application are quite large, and we are far within those tolerances, then the bolt holes will be matched drilled to align precisely within the vehicle. This is a 1 off application, we only have one vehicle and are doing this as part of a high efficiency and low emissions automotive research project.I've attached an up-close picture of my welds, they look like this pretty much everywhere, I don't have enough hands on experience with welding/aluminum to know whether these have effectively mated the two pieces.Last edited by EE51; 05-26-2014 at 11:32 PM.Reason: Picture Added
Reply:That's a interesting project wish I had access to high tech toys like that lol for building I could probally do that in 2 1/2hrs total
Reply:What would a properly designed hitch weigh out of steel?  You have the fancy tools...Don't take this the wrong way, but that looks like chit from here.  Aluminum is the wrong material for that type of application.  If you don't believe me, go find a big DIY store like Home Depot, Lowes, or Menards.  Walk through the parking lot and look under any aluminum trailers you find.  I bet you find more cracks than you can count.My name's not Jim....
Reply:Agree with Boost on all counts, aluminum is nice for a lot of things, hitches not being one of them.....Mike
Reply:Originally Posted by BoostinjdmWhat would a properly designed hitch weigh out of steel?  You have the fancy tools...Don't take this the wrong way, but that looks like chit from here.  Aluminum is the wrong material for that type of application.  If you don't believe me, go find a big DIY store like Home Depot, Lowes, or Menards.  Walk through the parking lot and look under any aluminum trailers you find.  I bet you find more cracks than you can count.
Reply:Hey guys, relax a little.I think this is a very interesting thread where design and theory meet the real world. EE clearly stated this is not going on the road for the next 15 years. This is a school research project, nothing more. They designed this to learn something and accomplish their limited stated goal. For that I give them high marks in research and gumption.He only asked how long should it take a professional to weld this, not how long it will last or can he start mass producing them. Sometimes we are too quick to jump to the future and give more advice than was asked for. I certainly appreciate everyone's concern about this hitch receiver as a consumer item and the reasons it would be a bad idea. And I learned a lot too, about the need to consider the HAZ and derating the welds and material. Great learning points, but I was impressed EE had already planned to re-heat treat. I'm no metallurgist to know if that is right or wrong, but at least he was aware. This is not our typical "bought me a 110v welder and going to build a trailer" thread.My son went to GaTech and they did some amazing (read "expensive, sometimes useless") stuff just to learn about practical application. Most of it was never intended for commercial production. But these guys are trying to learn and asking for information. So I suggest we continue helping them, answer their questions, AND give them "real world" advice in a friendly, positive way. My oldest son always took offense when someone said "real world". He would say, "if I'm not in the real world, where am I?".  I had to laugh a few years later when he told his sister "when you get in the real world . . ."!BTW, I hope EE51 posts his college and location. And some pictures of the hitch on the vehicle.Burt _____________________Miller Syncrowave 250Millermatic 211Miller 375 Plasma Cutter Hobart Handler 12010FtDrillBit.com
Reply:Good thread,   hopefully the OP has learned lots of real world facts from experienced pros here.  The exact type of things that are NOT learned or taught in school.   Advice forum years of real world observation and application.     This is why auto industry has so many recalls.    Engineers designing something that looks great on paper but excluding the real world applications and variables.   Your current design would result in millions of dollars in recalls and probably lawsuits from failure on a multitude if reasons others have noted here.    Hopefully you will share what you learned here with the class.     I'm no pro welder, but 25 years turning a wrench, I have seen more bad designs and engineering than I can count.       Sent from my SCH-I545 using TapatalkTiger Sales:  AHP Distributor    www.tigersalesco.comAHP200x; AHP 160ST; MM350P,  Spoolmatic 30A; Everlast PowerTig 185; Thermal Dynamics 60i plasma.  For Sale:  Cobra Mig 250 w/ Push-pull gun.  Lincoln Wirematic 250
Reply:Well, it certainly is an interesting thread.  I am under the impression that this Aluminum hitch is more of a "proof of concept" rendition than any "production prototype model", at least at this point.It did not become apparent why Aluminum was the material of choice until the revelation of it being tied to an electric vehicle.And, on a side note to the OP.  You are (by the nature of your student status) going to be rubbing elbows with some learned and erudite individuals.  When you are exposed to a new word, don't automatically think it was misspelled and then try to use it yourself and misspelling it in your text.  There is as huge difference of definition between "tenet" and "tenant".  Having a good, accurate vocabulary is not critical for most everyday functions in life, but when you are delving into advanced technical territory, the peer group changes, and you had better know what you are talking about and which words are apt for the subject matter.  Otherwise you come off in an Archie Bunker sort of way.Ever hear the saying "Strong As Aluminum?"  Me neither!
Reply:You don't want to know what I think.......zap!I am not completely insane..Some parts are missing Professional Driver on a closed course....Do not attempt.Just because I'm a  dumbass don't mean that you can be too.So DON'T try any of this **** l do at home.
Reply:Originally Posted by walkerweldOtherwise you come off in an Archie Bunker sort of way.
Reply:Originally Posted by duaneb55Who's Archie Bunker?
Reply:Originally Posted by Old SkoolEver hear the saying "Strong As Aluminum?"  Me neither!
Reply:If we dont think aluminum is strong why are they making aluminum receivers for trucks rated in the 10,000 lb range as in Trimax hitches. Aluminum Flat beds for Trucks, most all Semi trailers are made out of aluminum, Most horse trailers are made out of aluminum. So as technology evolves we see better material better process and better design. As for OP he's learning and seeing a foreseen future into things that might become something. So not to knock it its design seems to be well thought out. Is there room for improvement? Yes as we all have room for improvement, thats how we evolve to become better at what we do. Great Project!Last edited by OUTBACK FORGE; 05-27-2014 at 03:59 PM.GalenMiller TrailBlazer 302 EFIThermal Dynamics 252i w/WeldCraft WP 9F tig torch and foot controlThermal Dynamics Pak 52Millermatic 250 w/Spoolmate 30aLincoln SA-200 gas driven welder from grandfatherBlacksmith shop
Reply:Just because you can do something, it does not follow that you should do it.Aluminum has no resistance to fatigue(see fatigue limit).  Steel does.  Any cyclic load that's less than approximately 1/2 the yield strength does no harm to steel, in terms of fatigue damage.  Aluminum accumulates fatigue damage with every load cycle, regardless of the size of the applied load.  This makes it an inherently poor choice for any structure that is subjected to repeated loading and unloading, WITHOUT THOROUGH, ROUTINE INSPECTION.  In the examples you mention there are systems in place (DOT inspections for example)  that should find cracks when they occur in aluminum structures on commercial vehicles.  Commercial airplanes are fanatically inspected if the regulations are followed.  Yet we still see occasional failures where aluminum pieces fall off of planes because of fatigue cracks that weren't discovered and grew to the point of causing failure.Check some other posts on this forum for discussions of failures of aluminum trailers and flatbeds.  They all suffer from cracks and rapid corrosion.  Frequently the damage isn't repairable, at least not in a permanent sense.  I'd be curious to see if the fuel savings from lower weight in these commercial aluminum trailers is partially or totally offset by the higher maintenance costs and shorter lifespan.  The application in this case is for a battery powered consumer vehicle, that would in all likelihood not receive regular inspections.  Consumers are notorious for using and abusing vehicles, hitches, and trailers.  So, to utilize a material with poor fatigue properties in a consumer receiver hitch, is a bad decision.  (I don't even want to talk about the additional choice of bolting the receiver to a glass or carbon fiber reinforced polymer structural member, where creep may be a concern.)    Weight savings in this application has to take a second place to safety; and to accept a design simply because it meets the short term, static loading requirements is a demonstration of poor judgement.  Better fuel economy through weight reduction is a good avenue for exploration of design improvements.  But only so long as safety isn't sacrificed in the process.  Material and design changes have to be validated over the expected lifetime of the vehicle.  Ignore this at your peril. At the very least; that sophisticated modeling software should be used to predict the fatigue life of the structure; as welded and after PWHT of the entire structure to homogenize the mechanical properties of the structure.  Perhaps you'll see that through thickening some areas or adding some small reinforcement you can improve the fatigue life and produce a design that is likely to last the anticipated lifecycle of the vehicle.I'd feel remiss if I didn't mention corrosion as well.  Driving this hypothetical prototype in any locale where they apply road salt during the winter will dramatically shorten the useful life of this aluminum receiver hitch.  Magnesium Chloride solutions and regular old road salt applied to roads in the eastern USA would eat this hitch away in just a few winter seasons.  Couple stress with a corrosive environment and you have a recipe for catastrophic failure of this hitch.  Steel suffers from this as well; but the corrosion rates are much lower and the failure modes tend more towards yielding before catastrophic failure.  This creates greater opportunities to catch problems before they pass you going down the freeway at 60-70 mph.Just because it's a prototype doesn't mean that someone else, less-well informed, won't latch onto this idea and run with it.  Lord only knows who might read this post, and decide that they can turn that pile of scrap aluminum in their hobby shop into something resembling a receiver hitch.  Hopefully they read all these other posts and decide not to proceed. Originally Posted by OUTBACK FORGEIf we dont think aluminum is strong why are they making aluminum receivers for trucks rated in the 10,000 lb range as in Trimax hitches. Aluminum Flat beds for Trucks, most all Semi trailers are made out of aluminum, Most horse trailers are made out of aluminum. So as technology evolves we see better material better process and better design. As for OP he's learning and seeing a foreseen future into things that might become something. So not to knock it its design seems to be well thought out. Is there room for improvement? Yes as we all have room for improvement, thats how we evolve to become better at what we do. Great Project!
Reply:Originally Posted by OUTBACK FORGEIf we dont think aluminum is strong why are they making aluminum receivers for trucks rated in the 10,000 lb range as in Trimax hitches. Aluminum Flat beds for Trucks, most all Semi trailers are made out of aluminum, Most horse trailers are made out of aluminum. So as technology evolves we see better material better process and better design. As for OP he's learning and seeing a foreseen future into things that might become something. So not to knock it its design seems to be well thought out. Is there room for improvement? Yes as we all have room for improvement, thats how we evolve to become better at what we do. Great Project!
Reply:Zap, i agree the aluminum hitch is a bad idea. But i wouldn't wouldn't say it will never last. In a few years who knows what new things they will have that could aid in using aluminum for applications like that. People said we would never fly..land on the moon..build taller buildings..Airco Ac/Dc 300 HeliwelderMillerMatic 200 (stolen)Miller Maxstar 150STLMiller AEAD200LE (welding and generating power) Hobart MIG
Reply:Wow, I think everyone just grossly misinterpreted this thread.  The OP has stated very little about the competition.   For all we know the hitch may have been designed for a one time use to pull a specific load and reduce weight as much as possible.  It not like they are looking to start production for alum hitches to match the all new alum body F-150'sHe stated they are just learning to tig alum, and he didn't ask for critiques on his welds.  Just wants to know how long a "professional" would take to fabricate.  They likely have a cost/build aspect to the same competition.Way to take this way off course.
Reply:Willhunt, you have been here since 2004 and still don't know how a forum works? Airco Ac/Dc 300 HeliwelderMillerMatic 200 (stolen)Miller Maxstar 150STLMiller AEAD200LE (welding and generating power) Hobart MIG
Reply:QUOTE=SquirmyPug;4231561]Willhunt, you have been here since 2004 and still don't know how a forum works? [/QUOTE][Burt _____________________Miller Syncrowave 250Millermatic 211Miller 375 Plasma Cutter Hobart Handler 12010FtDrillBit.com
Reply:You seem like an intelligent fellow EE51 and you certainly took that first response in stride, so I have faith that you can take the constructive criticism and the rest that isn't so constructive.  The one thing you really need to keep in mind here is that a good majority of these guys HATE engineers, couple that with the fact that they see a trailer hitch made out of aluminum and they run for the torches and pitchforks thinking this thing is going out on the road.  You'll never be able to please everyone, especially on here, and nothing is every perfect (those are facts, not opinions)  People also tend to look at the very first post and skip over the fact that you later explain this is a design project for a purpose built vehicle that I'm going to presume isn't even road legal, most will think you intend to put an aluminum hitch under a 1-ton and put it on the road.Like I said, most of these guys hate, hate, HATE engineers, but that's just part of the profession.MikeConstans Fides et IntegritasLincoln Weldanpower 150 ACAirco Aircomatic MIGet CAV II w/ spoolgunMillermatic 30a wirefeeder
Reply:Originally Posted by Brink, M.E.Like I said, most of these guys hate, hate, HATE engineers, but that's just part of the profession.
Reply:Originally Posted by zapsterI myself would make it mandatory that anyone who wants to be a engineer has to spend a minimum of 10 years in a machine shop environment before they could be able to draw anything!Then they would know what works and what does not....zap!
Reply:Originally Posted by Brink, M.E."You can't fix stupid."
Reply:Originally Posted by BobWith it made of aluminum, I just don't think it would hold up. The bolts would pull through those holes even if some thing else didn't break.
Reply:That's an interesting, if unconventional, application of aluminum. It could be anodized or painted to deal with corrosion, although bolting it to a piece of carbon fiber just about guarantees corrosion at the interface. Duralac or lanolin can be used to prevent galvanic corrosion btw Alu and the fasteners. Putting a layer of fiberglass over the carbon where the aluminum plates contact the composite will help a lot also. Without any anticorrosion measures it will be fine for a year or three but eventually the chalking will compress and probably delaminate the composite.
Reply:Accidental post sorry Sent from my iPhone using Tapatalk
Reply:Here is a start to aluminum receivers. Granted they are pulling light weight stuff but still a ALUMINUM receiver.Also here is a great read on why we use Aluminum and what its capabilities are. This ties in what the OP is working on. The Future of what may come. We half to be open minded and not so closed off to change. http://www.rivcoproducts.com/product...cat=255&page=1http://www.golfcarcatalog.com/produc...ler-Hitch.htmlhttp://www.alueurope.eu/wp-content/u...Bookmarks1.pdfGalenMiller TrailBlazer 302 EFIThermal Dynamics 252i w/WeldCraft WP 9F tig torch and foot controlThermal Dynamics Pak 52Millermatic 250 w/Spoolmate 30aLincoln SA-200 gas driven welder from grandfatherBlacksmith shop
Reply:Link #1 a hitch for a Honda Goldwing motorcycleLink #2 a hitch for a golf cartLink #3 a reference guide from the European Aluminum AssociationI have counterpoints for each of the links you posted in support of the OP's prototype for a aluminum receiver hitch for a consumer passenger car.1 - motorcycle hitches are not commonplace and by virtual of their rarity present a much smaller threat to the motoring public.  Motorcycles are typically operated in fair weather, under clean road conditions, to pull minimal loads.  They are seldom used to tow a trailer loaded with heavy cargo or materials.  I'll assert that motorcyclists (or operators, if you prefer) are more diligent than the average cage driver when it comes to vehicle maintenance and inspection.  This offsets some of the risks of accumulating fatigue damage.  I've yet to meet someone on a bike riding in winter snow and ice, pulling a trailer.  So an aluminum hitch is unlikely to see exposure to the severe corrosion that is commonplace on a passenger vehicle.  I'm still not a fan of the idea, but for a motorcycle hitch I don't have nearly the objections that I do to a hitch on a passenger vehicle.  Fatigue cycles are likely to be lower, inspection more frequent, and corrosion a much less severe problem.  2 - Golf carts are not operated at high speeds on public roadways.  This is a total separate class of vehicle with a much different, and much lower risk profile in my opinion.  It's not a good example to discuss in this context.3 - The technical manual you posted strikes me as being a bit self-serving.  Aluminum producers are motivated by profit to encourage others to use their material.  That aside, The manual limits discussion to Commercial vehicles.  If you'll recall, my earlier post mentioned that commercial vehicles are subject to regular inspection and that this mitigates much of the risk of fatigue and corrosion related failures.  I've no problem with using aluminum in commercial applications because I think the risk is much lower due to frequent, mandatory inspections.  This is certainly true in Europe.  The section on cost savings of aluminum vs steel vehicle structures is regrettably lacking in any factual data to support the statements made.  I wish it had some as, I'd like to see it for myself.With regards to corrosion risks, the manual goes into great detail on the sources and countermeasures for corrosion in aluminum vehicle structures.  There's even washing recommendations, including rinsing the vehicles made from aluminum with De-ionized water.  This is probably a sound idea for any vehicle, but seems particularly important on an aluminum vehicle.In any case, none of the information provided is directed at the use of aluminum in a hitch for a small passenger vehicle.  You might make a case for using this material if you mandated that purchasers bring their vehicle back to the dealership or factory authorized service center for an annual inspection.  This would allow for routine inspection of the hitch and other components for damage related to fatigue or abuse.  Then you could remove or replace damaged hitches when necessary.  I suspect the seller/manufacturer would have to absorb this cost; in much the same way they've had to deal with extended warranties on electric or hybrid vehicles.  I don't see the consumer shouldering this  burden.In closing, I appreciate that you have brought some evidence to support the notion that an aluminum receiver hitch on a passenger vehicle is a sound idea.  But, speaking for myself, I remain unconvinced.  Your arguments and facts have failed to cause me to change my opinion.  An aluminum hitch on a passenger vehicle is a poor notion if implemented without a great deal of additional forethought and testing.  My intuition tells me that such additional work and investigation will prove my point.  There are already too many injuries and fatalities due to poorly maintained trailers pulled behind light trucks and passenger cars with excess load or compromised hitches.  Don't take my word for it.  Look around on the forum and search the internet for news stories about traffic accidents involving non-commercial trailers.Benson's Mobile Welding - Dayton, OH metro area - AWS Certified Welding Inspector
Reply:Well Ok but in this case it seems  a great deal of forethought has gone into it. This is essentially a prototype. I don't recall the guy making any grand statements about how all trailer hitches in the world should be aluminum, or asking whether aluminum should be used for a hitch. He wanted to know how far off they were on production welding benchmarks.Keeping the world safe from aluminum hitches is a noble calling but fundamentally seems like a crusade in search of a problem.
Reply:Originally Posted by OUTBACK FORGEHere is a start to aluminum receivers. Granted they are pulling light weight stuff but still a ALUMINUM receiver.Also here is a great read on why we use Aluminum and what its capabilities are. This ties in what the OP is working on. The Future of what may come. We half to be open minded and not so closed off to change. http://www.rivcoproducts.com/product...cat=255&page=1http://www.golfcarcatalog.com/produc...ler-Hitch.htmlhttp://www.alueurope.eu/wp-content/u...Bookmarks1.pdf
Reply:You could make a receiver hitch plenty strong out of aluminum. Being lighter than steel you can make up the difference by making it thicker. steel would be better anyway because more economical and less wear. I would have made the receiver longer so load would be distributed over more of frame.
Reply:Originally Posted by res0r9lm I would have made the receiver longer so load would be distributed over more of frame.