After a group meeting, the final decision between Aluminium 6061, Aluminium 6063, Cast Carbon Steel, and Carbon Steel 1023 was discussed. The group as a whole agreed that using any form of Steel would be too heavy of a material. This left the choice between the two grades of Aluminium. After some final research, we found that the cost of Aluminium 6063 is slightly more than 6061 but their properties are almost identical, however Aluminium 6063 is slightly heavier also. Both materials were had good joining properties, both could be welded through TIG (Tungsten Inert Gas) and MIG (Metal Inert Gas) welding.
This ultimately led to the decision that Aluminium 6061 should be used.
Aluminum 6061 can be found in a very wide range of products. A very common product would be a bicycle with a tubular frame. Here is an example of a bike using aluminium 6061.
The picture shows the front of the frame where three seperate parts of the bike meet together and are welded together. This is just above the front fork of the suspension. There would be a considerable amount of load going through this section of the bike. The weld is also very neat which suggests the parts are easily welded together.
For the crane, a hollow tubular frame would be welded together to form the Truss' that will join together to create the crane.
Here is an example of a tubular frame used on a race car. The frame is designed to be strong but lightweight which makes it good for its application.
http://www.gtbicycles.com/GTFiles/ProductImages//2000_1300_G10AVA1D_255.jpg
http://www.galmerinc.com/images/dsr_frame.png
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