%$&*$#% Alloy nipples
 

Years back, I bought a set of Campy Record/Mavic Open Pro wheels from Performance. I never had luck with commercially built wheels, but the wheelset was cheaper than buying the just the hubs. So, I thought: what can go wrong? Well, halfway through my first longer ride, I had to true the rear wheel on the side of the road. When I got back home, I re-tensioned it and it's been fine since. Until today. I started out on a 60+ mile ride and 1/4 mile from my home I heard a ping. A nipple popped on the rear wheel. I rode home and got another bike to do the ride. I went to replace the nipple and realized the broken one was alloy. I've owned these wheels for years and never noticed they had alloy nipples. They now have a little over 4,000 miles. This is my nice weather/longer distance bike. Replace all the nipples? What would you do?

If you know how to properly build, dish and tension wheels, then go for non-alloy nipples. That said, well, that is said. I was going to say something about the advantage of alloy nipples, but for the wee bit of rotational weight saved, what is the point. That said, not that the issue has presented itself, you will never be able to get past it, if you are anything like me. Bonne chance.

I've built a front wheel with alloy nipples, and eventually had the nipple heads break off of the body of the nipple. I've since learned that the spoke should extend through the whole nipple to reduce the chance of this. That wheel got brass nipples once a couple of alloy nipples broke.

I currently have a different front wheel with alloy nipples, and it's got a lot(?) of miles. Probably 10k or more? fwiw, the wheel has 36 spokes. No problems so far.

I never had the nerve to try alloy nipples on the rear wheel though. (and I'm not a heavy person) If your broken nipple was on the drive side, I'd probably start with just replacing that side with brass nipples. They get more tension and are more highly stressed.
A more pragmatic person might just decide to replace all of the alloy nipples as long as the wheel is getting re-tensioned and re-trued... but where's the adventure of that?? ;)

Steve in Peoria

I vote for replace all nipples with brass now. But it's from my point of view. I'm good at building wheels. I'm also very biased against aluminum nipples.

Last wheelset I had with alloy nipples, a few rear ones individually just kind of disintegrated. I replaced them all with brass.

Yup, broke on the drive side. I never thought about just replacing the drive side with brass. Half the work and I already have 1/16th done. This might be my first course of action.

Are the spokes long enough to go to the base of the nipple? Failures like this are often not a nipple material problem but a wheelbuilding problem with too short spokes - which will cause brass to eventually fail as well.

Alloy nipple failures unrelated to spoke length look like a crumbled nipple due to corrosion. I'll bet your problem is the first one.

I throw out every alloy nipple that show up in here. Just like Kontact sez they disintegrate with minor water exposure. Rebuild with some brass from a reputable company. Smiles, MH

The nipple broke right at the base and there were 2-3 threads passed the point where it broke.

I still have wheels that I built with DT alloy in the '80' s. Never had a problem. Still use them with nary a worry.

I have used aluminum nipples in three builds. The thing is that I used brass on the drive side because I knew the tension for Campy 10s was going to be huge if I had the non-drive wound up adequately. So I have aluminum nipples on only the front and the non-drive side of the rear.

2-3 threads of bare spoke is sticking out past where it broke?

Is the nipple dull and powdery looking? If not, and the spoke is long enough, I would replace it and chalk it up to bad luck.

I always got brass nipples and I never had problems. No corrosion snd the brass provides the needed "lubrication" at the threads and nipple wells.
What little weight you might save with aluminum nipples is just not worth it, if they would corrode and possibly seize on you.

Yes, to the first question
No, to the second.
It's already replaced. Gonna see what happens to the others. One more break and I'll replace the whole drive side.

I've heard that alloy nipples occasionally break.

Haven't ever seen a brass nipple break.

If you're posting to Bike Forums C&V, I highly doubt the extremely small weight advantage will make a difference in your riding.

Take the brass, leave the alloy.

I'd replace with brass now, then ride with confidence that problem won't arise again, the overall practicality of working on the wheel improves too,