Aerocoach Aeox Titan Wheel Failure

One of my viewers recently shared some shocking photographs of an Aerocoach Aeox Titan wheel following an amateur time trial event in the UK. These images reveal a catastrophic failure that exposes serious flaws in the manufacturing and design of these so-called high-end cycling components.

Aerocoach: Overhyped and Underperforming

Aerocoach, a UK-based company, touts itself as “experts” in the cycling industry. Their products are frequently showcased in publications like GCN, Cycling Weekly, and Bike Radar. Despite the hype, this incident raises serious doubts about their self-proclaimed expertise and the quality of their components.

The Incident: A Tale of Poor Engineering

After finishing the time trial, the rider noticed a disturbing looseness in the bike’s front end. Upon closer inspection, it became clear that the hub flanges of the Aeox Titan wheel had snapped in two locations at the same angular position. This kind of failure is not only unusual but also deeply concerning, especially given Aerocoach’s inflated claims.

Technical Analysis

Radial Lacing: A Recipe for Disaster

The Aeox Titan wheel is radially laced, a design choice that seems more about cutting corners than enhancing performance. Radial lacing can significantly increase the load around the spoke holes when exposed to adverse forces. Unlike cross-laced wheels, radial lacing fails to distribute forces evenly, leading to higher stress concentrations and an increased risk of failure.

Brittle Fracture: A Clear Sign of Inferior Quality

The photographs show a brittle fracture of the hub flanges, with no signs of elongation or ductile deformation. This type of failure points to a sudden, catastrophic break, characteristic of inferior materials that cannot withstand significant stress. It’s a glaring indication of poor quality control and substandard materials.

Casting vs. Forging: Cutting Costs at the Expense of Safety

Engineers who reviewed the photographs strongly suspect that the hub is cast, not forged. Casting is a cheaper manufacturing process that often results in weaker, brittle components. Forging, on the other hand, produces stronger and more durable parts. By opting for casting, Aerocoach has clearly prioritized cost-cutting over rider safety.

Machining Quality: A New Low

Engineers were unanimous in their assessment of the hub’s machining quality, describing it as ranging from “substandard” to “sh*te.” This poor craftsmanship likely led to stress risers—areas of concentrated stress—significantly increasing the likelihood of failure. Such shoddy workmanship is unacceptable, especially for a product marketed as high-end.

The photograph below shows the ridge that goes straight through the PCD of the spoke holes. This is in combination with a what appears to be a geometrical defect in part of the hub (indicated with an arrow).

Response from Aerocoach (or lack of it)

Aerocoach were asked for a response to the photographs and evidence presented. They did not respond to either this channel or the original owner of the wheelset.

Conclusion: Buyer Beware

The failure of the Aerocoach Aeox Titan wheel hub is a damning indictment of the company’s design and manufacturing standards. The combination of radial lacing, suspected casting, and abysmal machining quality has resulted in a brittle fracture, casting serious doubt on the reliability and safety of Aerocoach products.

Cyclists who invest in high-end equipment deserve confidence in the durability and quality of their components. This incident exposes Aerocoach’s blatant disregard for these principles, serving as a stark reminder to scrutinize not just the marketing hype but the actual engineering and manufacturing standards behind cycling products.

As more information becomes available and if Aerocoach deigns to provide an official response, it will be crucial to revisit this analysis. However, based on the evidence at hand, it is clear that Aerocoach’s reputation as “aero experts” is nothing more than hot air. Buyer beware.