Overview

For the wing’s main spar, I plan on using an aluminum trim channel. The two extruding sides will act as the spar caps to handle the bending moment while the connecting side will act as the shear web to handle the shear loads. Brackets will connect the spars of different subsections. Looks like most trim channel options use 6063 aluminum, but 6061 aluminum is about twice as strong with the same density so we should more strongly consider such options. Based on the material information, we want to develop a mass per length function for the spar.

Mass Function

Density = 2.7 g/cm^3 or 0.0030 slug/in^3

photo.heic

A = Height, B = Width, C = Thickness

Cross-Sectional Area = A * B - (B - C)(A - 2C)

Volume = Cross-Sectional Area * L = [A * B - (B - C)(A - 2C)] * L

Mass Per Inch = Density * Cross-Sectional Area * 1 = 0.0030 * [A * B - (B - C)(A - 2C)] slugs

If Square: Mass Per Inch = 0.0030 * [3 * S * T - 2 * T^2] slugs where S = side length and T = thickness

Options for Reference

https://www.homedepot.com/p/Everbilt-3-4-in-Wide-Inside-x-4-ft-Aluminum-Trim-Channel-Heavy-Duty-6545/332733638

https://www.lowes.com/pd/Hillman-3-8-in-W-x-4-ft-L-Mill-Finished-Aluminum-Weldable-Trim-Channel/3053591

https://www.metalsdepot.com/aluminum-products/aluminum-channel-6061

https://www.metalsupermarkets.com/product/aluminum-channel-6061/ ← I like this one