Duct Material Research

Owned by Nitish Baskar
Last updated: Mar 30, 2024 by Kaden Nguyen

Currently Planned: DUCT TO BUY 4 inch x 8 feet Aluminum Semi-Rigid Flexible Duct (Buy two)

https://www.amazon.com/Eastman-69028-ArmorFlex-Clamps-Length/dp/B07RL3V8JR/ref=sr_1_16?crid=37EJH80A9M89E&keywords=4%2Bin%2Bx%2B8%2Bft%2B,luminum%2Bduct&qid=1708198165&sprefix=4%2Bin%2Bx%2B8%2Bft%2Baluminum%2Bduc%2Caps%2C135&sr=8-16&th=1


Aluminum

Pros: lightweight, flexible, less heat absorption than steel, 


Cons: susceptible to damage from extreme temperatures, 


New Planned Intake Duct (cut in half for two 12.5ft.)


https://www.amazon.com/Air-Duct-Aluminum-Flexible-Ventilation/dp/B01F7Q5VIM/ref=sr_1_4_sspa?crid=SHDH912A13AJ&dib=eyJ2IjoiMSJ9.ESbdNxqZoArieVf3sP5QS-HV9JD2QgQioG6QX--sS-4jD9VeQ4_199H-naUGbPd28gfX8GosHHx4x1i7sGoYJrsvNwU0-9ctpN8UZCu9wwB8QsGk7RBFv3rJBXnHvdafxnHsmRvBCNk3dCSw1umCXmH8FnjMR_Ti_dGdYgOrt0BEniyI7MtThboJX1Ca1as_l9-vphGRtB2hlB3m0jzyI4VIZXPJU3MmSSHYdf7Ydl2p0rXJtv0O1imLselv6KlBorwEfpKSwh6nMcZKUJf0P4a3Yfr9qYnd7xgrQYmBFtI.AboZW39oB66-V19bnhdOrO8bsCB4Gyc1MRxnFNIKQNk&dib_tag=se&keywords=4in.%2B25ft%2Baluminum%2Bduct&qid=1711837512&sprefix=4in.%2B25ft%2Baluminum%2Bduct%2Caps%2C85&sr=8-4-spons&sp_csd=d2lkZ2V0TmFtZT1zcF9hdGY&th=1


https://www.amazon.com/Adjustable-Stainless-Steel-Clamps-Ducting/dp/B07HVBLVD2/ref=pd_bxgy_img_d_sccl_2/138-5952414-0723565?pd_rd_w=ID3vq&content-id=amzn1.sym.2b132e63-5dcd-4ba1-be9f-9e044543d59f&pf_rd_p=2b132e63-5dcd-4ba1-be9f-9e044543d59f&pf_rd_r=QTXCNM1ZMNRP2D1AP4B7&pd_rd_wg=FKbL0&pd_rd_r=92dda900-a112-4cf5-babd-67a40170df22&pd_rd_i=B07HVBLVD2&th=1


6in. Duct Exhaust


https://www.amazon.com/Air-Duct-Flexible-Ventilation-Register/dp/B07BMFVKJ6/ref=sr_1_7?crid=1Z6PV94PA2NQ&dib=eyJ2IjoiMSJ9.sF6E3omMXwc1rBeUGEz_jhHLr8qEp8HG_jmrv2bM26bgBzkBBxp2LvyNUhCqNSR574O0w1pF_BPVQu--yxvqe6CZoF1apdskMmHkUNvLJKtoZN0uirZUksm5Ow8tbCBCgagd5rMeKy2CiNM0NZ0QOPwj-6W-GkVKf5qmqAEXzObVq7Yiusb99egWhhQB6JKxoKjTCeYW7pDJjXv0xBinMzmA6taWqdRl1h6bNZsZzANW39h7_-SRH-QHtwOCLpoLKOd61CBcIIyln4pc4AATbLo3jfZEEgONdvKw1Vy0yZs.SPwyWPWuYQWQrwBX8ychZfTz1y9nn5pwQcInivymEmw&dib_tag=se&keywords=6in.%2Baluminum%2Bduct&qid=1711837940&sprefix=6in.%2Baluminum%2Bduc%2Caps%2C90&sr=8-7&th=1


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:

  1. Conventional air ducts (basic)
    1. Materials: solid (ex. aluminum) → occupies much more space in cars + uses large amount of thermal energy
  2. Twinsheet thermoformed air duct (advanced)


Types of duct formats: 

  1. 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
  1. 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
  1. 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


  1. 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:

  1. 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)
  1. 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:



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