It's incorrect to say that *any* metal that is cyclicly loaded will fatigue 
and fail eventually. Steel and titanium alloys have a fatigue limit, which 
means that there is an amplitude of stress below which the material will 
not fail no matter how many cycles of stress are applied. Aluminium, OTOH, 
does not have a fatigue limit and will eventually fail at any repeated 
stress. See for example, the diagram plotting stress against number of 
cycles to failure for steel and aluminium at 
http://en.wikipedia.org/wiki/File:S-N_curves.PNG. However, given proper 
design, the number of cycles to failure becomes extremely high. After all, 
there are still airlines flying DC-9s that are getting on for 40 years old, 
many airfreight 747s are over 30 years old, and the USAF is planning to 
keep B52s in the air until about 2040, by which time they will be getting 
on for 80 years old. And all those have aluminium airframes.

In about 40 years of riding, the only pair of handlebars I've had break 
were a pair where the handlebar bag mount looped over the top of the bars 
each side of the stem and (I discovered after the bars broke) had worn a 
substantial groove in the bar. Outside of bars being damaged like that, I 
only replace bars if they've been crashed and bent. I think the oldest pair 
I have in use are about 30 years old - Cinelli Campione del Mondo.

On Tuesday, 19 March 2013 08:10:09 UTC+11, William wrote:
>
> You pose two questions:
>
> 1.  Anyone know anything about aluminum bar life?
>
> I know a little bit about fatigue life of materials.  Any metal that is 
> cyclicly loaded will fatigue and fail eventually. 
>

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