Todd-
after first agreeing with everything posted to date, here's an orthogonal view that might offer an enterprising young man like your self a business opportunity to serve the top 5-10% of the market that constitute what I call the "bleeding edge" market.
first and foremost it's important to recognize that what is commonly referred to as "airfoil" tubing is NOT, it's correctly called
"streamline" tubing. I've included for reference an image of p.63 of the current Aircraft Spruce catalog illustrating that even suppliers that service the lowspeed aircraft and related markets refer to it as streamline tubing in their catalogs. it's been a while since I've looked at a copy of the
streamline tubing Mil Spec so don't remember if Mil-T-6736 will get you there or it's just the specification on the 4130; pulling a copy is time well spent and you'll find the detailed information provided fascinating.
streamline tubing's origins date back to the late 1920's and/or early 1930's. stronger more reliable solutions were required for structural elements in the airstream and round tubing's drag coefficient was then as now unacceptable. the country's answer was a comprimise solution that balanced the then state-of-the-art forming capability, the properties of 4130, the structural properties of the resulting section, and last but not least the low speed drag coefficient of the resulting section. more than eighty years later it still remains an outstanding material when properly used!!
like all cost driven comprimises in a performance driven market, the comprimes made 80+ years ago in the specification for
streamline tubing present potential opportunities in a "bleeding edge market". the low speed drag coefficient for
streamline tubing while a factor of three better than a round tubes does not compare well with real fairings such as NACA 0008, or NACA 0010, or NACA 0012, or even NACA 0014. better catalogs for
streamline tubing frequently include a figure of merit column labeled equivalent tension round tubing, equivalent compression round tubing, and weight per foot. the catalogs are attempting to provide useable guidance on column buckling capability of the
streamline tubing. the mil spec for streamline tubing and better texts on aircraft structures have the actual moments of inertia so the approximate values in the catalogs don't have to be used. columns (suspension arms) always fail in the direction of minimum moment of interia and as a consequence drives sizing decisions on the use of
streamline tubing for suspension pieces.
given some design work and a little fabrication cleverness, it's my sense a lower drag AND lower weight per foot fabricated all steel product (for GCR compliance) should be possible for the bleeding edge market. a quick look at the tables will confirm that the equivalent compression round tube diameter is always smaller than the thickness of the
streamline tube meaning smaller frontal area for the drag calculation (in addition to the vastly improved drag coefficient from use of one of the real fairing profiles) and lower weight assuming a 0.005'-0.010" fairing implementation with intermittent ribs. no end fittings to get the loads into the fabricated all steel product would be required, lighter than all current approaches used with
streamline tubing. the product would work particularly well on modern push-rod suspension cars where the A-arm rod-ends see almost no bending loads, only tesnion and compression with the resulting much smaller threaded shank diameters.
projected market size is unknown and likely small. YMMV.
Art
artesmith@earthlink.net