Material Selection: Thin Flexible Metal Rod for 6K Cycle

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Discussion Overview

The discussion revolves around selecting a thin flexible metal rod that can withstand 6,000 cycles of bending without breaking or returning to its original shape. Participants explore material properties relevant to flexibility, ductility, and malleability, considering both theoretical and practical aspects of material selection.

Discussion Character

  • Exploratory
  • Technical explanation
  • Debate/contested

Main Points Raised

  • One participant seeks a metal rod that can bend 45 degrees in both directions and maintain its shape after deformation, specifically for 6,000 cycles.
  • Another participant clarifies the definitions of flexibility, ductility, and malleability, suggesting that the desired material should be ductile and malleable to withstand both tension and compression.
  • Gold is proposed as an ideal material due to its high ductility and malleability, although cost is noted as a potential issue.
  • Iron, nickel, and tin are suggested as alternative materials if cost is a concern.
  • A participant mentions that pure copper and tin only lasted around 1,000 cycles and shares their experience of switching to a goose neck design to reduce stress on the metal.
  • Another suggestion is made to try a 300 series stainless steel as a potential material option.

Areas of Agreement / Disagreement

Participants express various viewpoints on suitable materials, with no consensus reached on a single best option. There are differing opinions on the effectiveness of different metals and designs for achieving the desired cycle life.

Contextual Notes

Participants highlight the importance of understanding the distinctions between ductility and malleability, as well as the implications of material choice on performance and longevity under cyclic loading.

Robertcamping
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I am trying to find a thin flexible metal rod that does not have a spring back property and be able to bend 45 deg. per side for 6K cycle. I tried 0.7 mm galvanized steel rod but not getting the cycle needed. Think of paper clip that and be bend 6K times without breaking. Once bend to a shape, it stays put. Can anyone recommend me a material that will meet that requirement.
 
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"Flexible" is a broad term covering both maleable and and spring metals. Since you want it to stay put, you're looking for something that's ductile, capable of being deformed (tension) plastically without fracture, and maleable, capable of being deformed (compression) plastically without fracture. Since you specified a rod, it will be undergoing both tension and compression during it's 6k cycles.

Ductility and maleability are not synonomous, and some materials are good in one but poor in the other. Gold is both the most ductile and maleable of all metals, followed by silver.

I'd go for the gold! It's a pretty good conductor, too. If cost is an issue, try iron, nickel, or tin (pure forms, not the alloys).
 
mugaliens said:
"Flexible" is a broad term covering both maleable and and spring metals. Since you want it to stay put, you're looking for something that's ductile, capable of being deformed (tension) plastically without fracture, and maleable, capable of being deformed (compression) plastically without fracture. Since you specified a rod, it will be undergoing both tension and compression during it's 6k cycles.

Ductility and maleability are not synonomous, and some materials are good in one but poor in the other. Gold is both the most ductile and maleable of all metals, followed by silver.

I'd go for the gold! It's a pretty good conductor, too. If cost is an issue, try iron, nickel, or tin (pure forms, not the alloys).


Thanks for the suggesting. It makes sense. I tried using pure Copper, and Tin. It only lasted around 1K cycle. I decided to use a goose neck which is less stress on the metal which turned out OK.
 
I'd suggest trying a 300 series stainless steel.
 

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