Try 4340 or 8740. Don't know about the cost, but the Metallic Materials Properties
Development and Standardization (MMPDS) manual says these can substitute for 4140. You can get a free download here: http://www.everyspec.com/FAA/FAA-General/DOT-FAA-AR-MMPDS-01-JAN2003_24102/
metengr,
Corrosion is part of the issue, but I can figure out a way around that; i.e. use of sealants or coatings to mitigate. The customer wants the DBTT values. Is there a way to go back to the customer and ask them to reconsider? Or is there a polite way to say DBTT is little value and this...
Another one you could bring up is when you weld galvanized pipe, it becomes a health hazard. Any time your work on galvanized pipe, cutting, milling , drilling, etc., the coating becomes airborne and can get into your lungs.
Unfortunately quite the opposite. If you apply an epoxy coating with a primer, such as one from Akzo-Nobels' 10-P4-3, or 466-23 Series topcoat that would probably do it. You can also use PR1776 sealant from PPG aerospace between the two parts to mitigate the corrosion.
I'm a non-metals guy (Plastics, composites) in a metals world. We are supplying parts to a new aerospace program and need to ensure the metals we are using are above a certain DBTT. Is there a place where I can look these up? Thanks.