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Cons: susceptible to damage from extreme temperatures,
New Planned Intake Duct (cut in half for two 12.5ft.)
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6in. Duct Exhaust
Ducts Material Research
Purpose of air ducts:
- Controls transfer of air flow into and out of the occupant compartment of automobiles + reduces noise/vibration significantly
Categories of ducts in cars:
- Conventional air ducts (basic)
- Materials: solid (ex. aluminum) → occupies much more space in cars + uses large amount of thermal energy
- Twinsheet thermoformed air duct (advanced)
Types of duct formats:
- Flexible air ducts
- Common materials: PVC, polyethylene (plastics)
- Pros:
- Lightweight
- Good for tight spaces
- Less expensive
- Easy to install
- Resistant to corrosion
- Cons:
- More airflow issues/collapses/kinks from flexible material
- Not as durable as metal ducts
- Not ideal for high-temperature environments
- Sheet metal air ducts
- Common materials: galvanized steel, aluminum (lightweight + easier to install)
- Pros:
- Durable
- Non-porous → naturally inhibits mold and bacteria growth for improved air quality
- Smooth surface for cleaning
- Cons:
- Expensive
- Fiberglass-lined air ducts
- Common materials: fiberglass, fiberglass-reinforced plastic (FRP)
- Pros:
- Durable
- Lightweight
- Corrosion resistant
- Can handle high pressure
- Insulation + sound muffling
- Cons:
- Risk of releasing fiberglass particles into air
- Porous surfaces - promotes mold + bacteria
- Fiberboard air ducts
- Common materials: strands of fiberglass bonded with resin + laminated by a metal foil exterior
- Pros:
- Less expensive
- Cons:
- Foster mold + mildew growth (especially in humid environments) → requires regular maintenance + monitoring
Material properties:
- Aluminum
- Pros:
- Good material properties
- Low density (lightweight) compared to galvanized steel
- Non-toxic
- High thermal conductivity
- Excellent corrosion resistance
- Easily cast, machined, and formed
- Non-magnetic
- Non-sparking
- 2nd most malleable metal
- 6th most ductile metal
- Less expensive
- Cons:
- Weak without combining with other metals (ex. copper, manganese, silicon)
- Galvanized steel (steel with zinc coating for extra corrosion resistance compared to steel)
- Pros:
- Durable
- Rust-resistant
- Corrosion resistance to concrete, mortar, lead, tin, zinc, and aluminum
- Non-toxic
- High melting point of 200 degrees Celsius
- High tensile strength of 510-600 MPa
- Long life span of 50+ years in medium environments and 20+ years in wet environments
- Cons:
- Corrosive to all metals except specified above + resistance depends significantly on the environment (ex. rain, dew, fog, condensation) + thickness of zinc coating
Sources:
- https://automotive.trocellen.com/automotive-air-duct/
- https://www.angi.com/articles/types-of-ductwork.htm
- https://www.rsc.org/periodic-table/element/13/aluminium#:~:text=It%20has%20low%20density%2C%20is,easily%20cast%2C%20machined%20and%20formed.
- https://www.gsa.gov/real-estate/historic-preservation/historic-preservation-policy-tools/preservation-tools-resources/technical-procedures/galvanized-iron-and-steel-characteristics-uses-and-problems
- https://www.xometry.com/resources/materials/galvanized-steel/