aluminum

112 Articles

Robotic Platform Is Open Sourced And User Friendly

September 26, 2022 by 9 Comments

Having a 3D printer or a CNC machine available for projects is almost like magic. Designing parts in software and having them appear on the workbench is definitely a luxury. But for a lot of us, these tools aren’t easily available and projects that use them can be out-of-reach. That’s why one of the major design goals of this robotics platform was to use as many off-the-shelf components as possible.

The robot is called the OpenScout and, as its name implies, intends to be a fully open-source robotics platform for a wide range of use cases. It uses readily-available aluminum extrusion as a frame, which bolts together without any other specialized tools like welders. The body of the robot is articulating, helping it navigate uneven terrain outdoors. The specifications also call for using an Arduino to drive the robot, although there is plenty of space in the robot body to house any robotics platform you happen to have on hand.

For anyone looking to get right into the useful work of what robots can do, rather than spending time building up a platform from scratch, this is an excellent project. It’s straightforward and easy to build without many specialized tools. The unique articulating body design should make it effective in plenty of environments. If you do have a 3D printer, though, that opens up a lot of options for robotics platforms.

Nanoparticles Rip Hydrogen From Water

September 5, 2022 by 38 Comments

Hydrogen fuel is promising, and while there’s plenty of hydrogen in the air and water, the problem is extracting it. Researchers have developed a way to use aluminum nanoparticles to rip hydrogen out of water with no additional energy input. It does, however, require gallium to enable the reaction. The reaction isn’t unknown (see the video below), but the new research has some interesting twists.

Aluminum, of course, is cheap and plentiful. Gallium, not so much, but the process allows recovery and reuse of the gallium, so that makes it more cost-effective. There is a patent pending for the process and — of course — the real trick is making the aluminum nanoparticles. But if you have that, this is a simple way to extract hydrogen from water with no extra energy and at room temperature. Since the reaction of creating aluminum oxide and releasing hydrogen with gallium is pretty well-known, it appears the real research here is determining the optimal properties of the aluminum and the ratio of aluminum to gallium.

While gallium isn’t a common item around the typical hacker’s workshop — unless you count the stuff bound up in semiconductors — it isn’t that expensive and it is relatively easy to handle. Hydrogen, though, not so much — so if you do decide to use this method to produce hydrogen, be careful!

We’ve seen gallium robots and even an antenna. So if you do get some of the liquid metal, there are plenty of experiments to try.

Dead Solar Panels Are The Hottest New Recyclables

July 19, 2022 by 99 Comments

When it comes to renewable energy, there are many great sources. Whether it’s solar, wind, or something else, though, we need a lot of it. Factories around the globe are rising to the challenge to provide what we need.

We can build plenty of new solar panels, of course, but we need to think about what happens when they reach end of life. As it turns out, with so much solar now out in the field, a major new recycling industry may be just around the corner.

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Watching A Boat Get Welded Together Is Workshop ASMR

July 11, 2022 by 33 Comments

If you’ve been on the Internet long enough to know about Hackaday, we’ll wager you’re familiar with the concept of autonomous sensory meridian response (ASMR) — a tingling sensation in the scalp that’s said to be triggered by certain auditory stimuli. There are countless videos on YouTube that promise to give you “the tingles” using everything from feather dusters to overly starched shirts, but for us, the tool of choice is apparently a Lincoln Electric Magnum PRO 100SG spool gun in the hands of [Bob].

You’ll want a friend to help wrangle the panels.

Admittedly we can’t promise the latest Making Stuff video will induce a euphoric physical sensation for all viewers, but at the very least, we think you’ll agree that watching [Bob] and his brother methodically welding together the twelve foot hull of what will eventually be a custom jet boat is strangely relaxing.

While we usually associate [Bob] with scratch builds, this time he’s actually working his way through a commercial kit. Sold by Jet Stream Adventure Boats, the kit includes the pre-cut aluminum panels that make up the hull, stringers, and top deck — niceties like a windshield and seats are offered as extras. The engine and jet drive need to be salvaged from an existing personal watercraft (PWC), but that will have to wait for a future video. For now, there’s a boat-load (get it?) of tack welding to be done.

The build process looks to go pretty smoothly, except for when they attempt to put the bow of the boat together. Unable to get the two side panels to meet properly, [Bob] eventually has to contact the manufacturer. After some back and forth, it turns out that a bit must have broken on the CNC when the hull panel went through, as a key cut was made nearly 8 inches (20 cm) too short. He was able to complete the cut with a jigsaw and continue on with the build, but we’re still scratching our heads at how this wasn’t caught before it got shipped out.

It won’t be the first homemade boat we’ve covered, but given [Bob]’s attention to detail, we’re particularly excited to see how this one develops in future videos. Especially since he’s foolishly bravely asked the commenters to come up with a name for his new craft.

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Square Cuts On Aluminum Extrusion, No Mill Required

May 20, 2022 by 53 Comments

If you’re looking for the perfect excuse to buy that big, beautiful Bridgeport mill, we’ve got some bad news: it’s not going to be making perfectly square end cuts on aluminum extrusion. Sadly, it’s much more cost-effective to build this DIY squaring jig, and search for your tool justification elsewhere.

There’s no doubting the utility of aluminum extrusion in both prototyping and production builds, nor that the versatile structural members often add a bit of class to projects. But without square cuts, any frames built from them can be seriously out of whack, leading to misery and frustration down the road. [Midwest Cyberpunk]’s mill-less solution uses a cheap Harbor Freight router as a spindle for a carbide endmill, riding on a laser-cut acrylic baseplate fitted with wheels that ride in the V-groove of — you guessed it — aluminum extrusions. A fence and clamping system holds the extrusion firmly, and once trammed in, the jig quickly and easily squares extrusions that have been rough cut with a miter saw, angle grinder, or even a hacksaw. Check out the video below for a peek at the build details.

We love the simplicity and utility of this jig, but can see a couple of areas for improvement. Adding some quick-throw toggle clamps would be a nice touch, as would extending the MDF bed and fence a bit for longer cuts. But even as it is, this tool gets the job done, and doesn’t break the bank like a mill purchase might. Still, if your heart is set on a mill, who are we to stand in the way?

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How To Solder To Aluminum, Easily

March 6, 2022 by 53 Comments

[Ted Yapo] shared a method of easily and conveniently soldering to aluminum, which depends on a little prep work to end up only slightly more complex than soldering to copper. A typical way to make a reliable electrical connection to aluminum is to use a screw and a wire, but [Ted] shows that it can also be done with the help of an abrasive and mineral oil.

Aluminum doesn’t solder well, and that’s because of the oxide layer that rapidly forms on the surface. [Ted]’s solution is to scour the aluminum with some mineral oil. The goal is to scrape away the oxide layer on the aluminum’s surface, while the mineral oil’s coating action prevents a new oxide layer from immediately re-forming.

After this prep, [Ted] uses a hot soldering iron and a blob of solder, heating it until it sticks. A fair bit of heat is usually needed, because aluminum is a great heat conductor and tends to be lot thicker than a typical copper ground plane. But once the aluminum is successfully tinned, just about anything can be soldered to it in a familiar way.

[Ted] does caution that mineral oil can ignite around 260 °C (500 °F), so a plan should be in place when using this method, just in case the small amount of oil catches fire.

This looks like a simple technique worth remembering, and it seems easier than soldering by chemically depositing copper onto aluminum.

Retrotechtacular: Understanding The Strength Of Structural Shapes

February 3, 2022 by 13 Comments

Strength. Rigidity. Dependability. The ability to bear weight without buckling. These are all things that we look for when we build a mechanical structure. And in today’s Retrotechtacular we take a closer look at the answer to a question: “What’s in A Shape?”

As it turns out, quite a lot. In a wonderful film by the prolific Jam Handy Organization in the 1940’s, we take a scientific look at how shape affects the load bearing capacity of a beam. A single sided piece of metal, angle iron, C-channel, and boxed tubing all made of the same thickness metal are compared to see not just just how much load they can take, but also how they fail.

The concepts are then given practical application in things that we still deal with on a daily basis: Bridges, cars, aircraft, and buildings. Aircraft spars, bridge beams, car frames, and building girders all benefit from the engineering discussed in this time capsule of film.

None of the concepts in this video are suddenly out of date, because while our understanding of engineering has certainly progressed since this film was made, these basic concepts remain the same. As such, they will apply to any structural or mechanical devices that we make, be it 3d printed, CNC routed, welded, glued, vacuum formed, zip tied, duct taped, bailing wired, or hot glued.

Keep your eyes open for a wonderful sights and sounds of a rare Boeing 314 Clipper landing on water and a 1920’s Buffalo Springfield Steam Roller demonstrating how wonderful the film’s sponsor, Chevrolet, makes their automobile frames.

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