Laser Cutters: Where’s The Point?

August 14, 2024 by Al Williams 31 Comments

It is funny how when you first start doing something, you have so many misconceptions that you have to discard. When you look back on it, it always seems like you should have known better. That was the case when I first got a low-end laser cutter. When you want to cut or engrave something, it has to be in just the right spot. It is like hanging a picture. You can get really close, but if it is off just a little bit, people will notice.

The big commercial units I’ve been around all had cameras that were in a fixed position and were calibrated. So the software didn’t show you a representation of the bed. It showed you the bed. The real bed plus whatever was on it. Getting things lined up was simply a matter of dragging everything around until it looked right on the screen.

Today, some cheap laser cutters have cameras, and you can probably add one to those that don’t. But you still don’t need it. My Ourtur Laser Master 3 has nothing fancy, and while I didn’t always tackle it the best way, my current method works well enough. In addition, I recently got a chance to try an XTool S1. It isn’t that cheap, but it doesn’t have a camera. Interestingly, though, there are two different ways of laying things out that also work. However, you can still do it the old-fashioned way, too. Continue reading “Laser Cutters: Where’s The Point?” →

Wacky Science: Using Mayonnaise To Study Rayleigh-Taylor Instability

August 14, 2024 by Maya Posch 9 Comments

Sometimes a paper in a scientific journal pops up that makes you do a triple-take, case in point being a recent paper by [Aren Boyaci] and [Arindam Banerjee] in Physical Review E titled “Transition to plastic regime for Rayleigh-Taylor instability in soft solids”. The title doesn’t quite do their methodology justice — as the paper describes zipping a container filled with mayonnaise along a figure-eight track to look at the surface transitions. With the paper paywalled and no preprint available, we have to mostly rely the Lehigh University press releases pertaining to the original 2019 paper and this follow-up 2024 one.

Rayleigh-Taylor instability (RTI) is an instability of an interface between two fluids of different densities when the less dense fluid acts up on the more dense fluid. An example of this is water suspended above oil, as well as the expanding mushroom cloud during a explosion or eruption. It also plays a major role in plasma physics, especially as it pertains to nuclear fusion. In the case of inertial confinement fusion (ICF) the rapidly laser-heated pellet of deuterium-tritium fuel will expand, with the boundary interface with the expanding D-T fuel subject to RTI, negatively affecting the ignition efficiency and fusion rate. A simulation of this can be found in a January 2024 research paper by [Y. Y. Lei] et al.

As a fairly chaotic process, RTI is hard to simulate, making a physical model a more ideal research subject. Mayonnaise is definitely among the whackiest ideas here, with other researchers like [Samar Alqatari] et al. as published in Science Advances opting to use a Hele-Shaw cell with dyed glycerol-water mixtures for a less messy and mechanically convoluted experimental contraption.

What’s notable here is that the Lehigh University studies were funded by the Lawrence Livermore National Laboratory (LLNL), which explains the focus on ICF, as the National Ignition Facility (NIF) is based there.

This also makes the breathless hype about ‘mayo enabling fusion power’ somewhat silly, as ICF is even less likely to lead to net power production, far behind even Z-pinch fusion. That said, a better understanding of RTI is always welcome, even if one has to question the practical benefit of studying it in a container of mayonnaise.

Ryobi Battery Pack Gives Up Its Secrets Before Giving Up The Ghost

August 14, 2024 by Dan Maloney 44 Comments

Remember when dead batteries were something you’d just toss in the trash? Those days are long gone, thankfully, and rechargeable battery packs have put powerful cordless tools in the palms of our hands. But when those battery packs go bad, replacing them becomes an expensive proposition. And that’s a great excuse to pop a pack open and see what’s happening inside.

The battery pack in question found its way to [Don]’s bench by blinking some error codes and refusing to charge. Popping it open, he found a surprisingly packed PCB on top of the lithium cells, presumably the battery management system judging by the part numbers on some of the chips. There are a lot of test points along with some tempting headers, including one that gave up some serial data when the battery’s test button was pressed. The data isn’t encrypted, but it is somewhat cryptic, and didn’t give [Don] much help. Moving on to the test points, [Don] was able to measure the voltage of each battery in the series string. He also identified test pads that disable individual cells, at least judging by the serial output, which could be diagnostically interesting. [Don]’s reverse engineering work is now focused on the charge controller chip, which he’s looking at through its I2C port. He seems to have done quite a bit of work capturing output and trying to square it with the chip’s datasheet, but he’s having trouble decoding it.

This would be a great place for the Hackaday community to pitch in so he can perhaps get this battery unbricked. We have to admit feeling a wee bit responsible for this, since [Don] reports that it was our article on reverse engineering a cheap security camera that inspired him to dig into this, so we’d love to get him some help.