Here's a tidbit of info that I was suspicious of but uncertain about from
this site
Quote:
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Aluminum and steel will always react and corrode when put together.
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My suggestion is once (maybe if?) you get the pulley off, have the pulley hole oversized and get a steel insert pressed into the aluminum. It is possible there is a better choice of metals, just make sure whatever metal is in contact with the motor shaft, that there won't be a reaction between them.
I wonder the price difference (and less total aggravation) if you have a new pulley made from steel? It's sounding possible the aluminum pulley is going to have to be cut off.
For what it's worth, when aluminum is cast in a die cast machine, steel is used for the die, but extremes are taken to make sure the aluminum doesn't bond with the steel; namely after EVERY CAST the die is sprayed with a solution of water and oil. The oil apparently slows down the tendency of the molten aluminum to bond with the steel, but yet it still occasionally happens. When this does happen, the aluminum has to be manually carved out of the die.