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)

2.  

   1. Materials: solid (ex. aluminum) → occupies much more space in cars + uses large amount of thermal energy

3. 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:

• 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/