On Monday, March 10, 2003, at 07:58 PM, John Carmack wrote:
Semi-related: Devcon makes some epoxies specifically formulated for bonding Aluminum (the oxide layer is an issue with some epoxies, leading to bond failure). They also make some epoxies that have a cured state that's relatively pliable (but still very strong), so fatigue failure due to cycling is less likely. I designed and build some aluminum electromagnets potted in a Devcon epoxy formulated for good heat resistance, good thermal and mechanical cycling behavior, and good bonding to aluminum. I can try to find the exact product if you'd like, or you could talk direct to one of their specialists - the guy I worked with was extremely helpful, and they might have something even better suited to your purposes.
If you are ever bridging much of a gap or making a filet, you need to add some kind of fibers to epoxy. We use cotton flox for most things, as it is nice and easy to work with, but chopped glass fiber is stronger. Chopped carbon fibers are even stronger, but you shouldn't use carbon fibers in contact with aluminum, because you get galvanic corrosion.
......Andrew
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