Preventing Galvanic Corrosion In Water Cooling Loops

April 20, 2025 by Maya Posch 8 Comments

Water is an excellent coolant, but the flip side is that it is also an excellent solvent. This, in short, is why any water cooling loop is also a prime candidate for an interesting introduction to the galvanic metal series, resulting in severe corrosion that commences immediately. In a recent video by [der8aer], this issue is demonstrated using a GPU cold plate. The part is made out of nickel-plated copper and features many small channels to increase surface area with the coolant.

The surface analysis of the sample cold plate after a brief exposure to distilled water, showing the deposited copper atoms. (Credit: der8auer, YouTube) — The surface analysis of the sample cold plate after a brief exposure to distilled water shows the deposited copper atoms. (Credit: der8auer, YouTube)

Theoretically, if one were to use distilled water in a coolant loop that contains a single type of metal (like copper), there would be no issue. As [der8auer] points out, fittings, radiators, and the cooling block are nearly always made of various metals and alloys like brass, for example. This thus creates the setup for galvanic corrosion, whereby one metal acts as the anode and the other as a cathode. While this is desirable in batteries, for a cooling loop, this means that the water strips metal ions off the anode and deposits them on the cathode metal.

The nickel-plated cold plate should be immune to this if the plating were perfect. However, as demonstrated in the video, even a brief exposure to distilled water at 60°C induced strong galvanic corrosion. Analysis in an SEM showed that the imperfect nickel plating allowed copper ions to be dissolved into the water before being deposited on top of the nickel (cathode). In a comparison with another sample that had a coolant with corrosion inhibitor (DP Ultra) used, no such corrosion was observed, even after much longer exposure.

This DP Ultra coolant is mostly distilled water but has glycol added. The glycol improves the pH and coats surfaces to prevent galvanic corrosion. The other element is benzotriazole, which provides similar benefits. Of course, each corrosion inhibitor targets a specific environment, and there is also the issue with organic films forming, which may require biocides to be added. As usual, water cooling has more subtlety than you’d expect.

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China Hosts Robot Marathon

April 20, 2025 by Al Williams 7 Comments

China played host to what, presumably, was the world’s first robot and human half-marathon. You can check out the action and the Tiangong Ultra robot that won in the video below. The event took place in Beijing and spanned 21.1 km. There was, however, a barrier between lanes for humans and machines.

The human rules were the same as you’d expect, but the robots did need a few concessions, such as battery swap stops. The winning ‘bot crossed the finish line in just over 160 minutes. However, there were awards for endurance, gait design, and design innovation.

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Hackaday Links: April 20, 2025

April 20, 2025 by Dan Maloney 4 Comments

We appear to be edging ever closer to a solid statement of “We are not alone” in the universe with this week’s announcement of the detection of biosignatures in the atmosphere of exoplanet K2-18b. The planet, which is 124 light-years away, has been the focus of much attention since it was discovered in 2015 using the Kepler space telescope because it lies in the habitable zone around its red-dwarf star. Initial observations with Hubble indicated the presence of water vapor, and follow-up investigations using the James Webb Space Telescope detected all sorts of goodies in the atmosphere, including carbon dioxide and methane. But more recently, JWST saw signs of dimethyl sulfide (DMS) and dimethyl disulfide (DMDS), organic molecules which, on Earth, are strongly associated with biological processes in marine bacteria and phytoplankton.

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MilliForth-6502, A Forth For The 6502 CPU

April 20, 2025 by John Elliot V 18 Comments

Forth is popular on small computers because it is simple to implement, yet quite powerful. But what happens when you really need to shrink it? Well, if your target is the 6502, there’s milliForth-6502.

This is a port of milliForth, which is a fork of sectorforth. The sectorforth project set the standard, implementing a Forth so small it could fit in a 512-byte boot sector. The milliForth project took sectorforth and made it even smaller, weighing in at only 336 bytes. However, both milliForth and sectorforth are for the x86 architecture. With milliForth-6502, [Alvaro G. S. Barcellos] wanted to see how small he could make a 6502 implementation.

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A 3D printer frame made of red plastic is shown on the left-hand side of the image. On the right-hand side, there is a large motor with a plastic frame attached to the frame. Next to the 3D printer, a blue plastic mesh is being fed through a red plastic frame.

The Most Printable 3D Printer Yet

April 20, 2025 by Aaron Beckendorf 13 Comments

Despite the best efforts of the RepRap community over the last twenty years, self-replicating 3D printers have remained a stubbornly elusive goal, largely due to the difficulty of printing electronics. [Brian Minnick]’s fully-printed 3D printer could eventually change that, and he’s already solved an impressive number of technical challenges in the process.

[Brian]’s first step was to make a 3D-printable motor. Instead of the more conventional stepper motors, he designed a fully 3D-printed 3-pole brushed motor. The motor coils are made from solder paste, which the printer applies using a custom syringe-based extruder. The paste is then sintered at a moderate temperature, resulting in traces with a resistivity as low as 0.001 Ω mm, low enough to make effective magnetic coils.

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Low Cost Oscilloscope Gets Low Cost Upgrades

April 20, 2025 by Bryan Cockfield 31 Comments

Entry-level oscilloscopes are a great way to get some low-cost instrumentation on a test bench, whether it’s for a garage lab or a schoolroom. But the cheapest ones are often cheap for a reason, and even though they work well for the price they won’t stand up to more advanced equipment. But missing features don’t have to stay missing forever, as it’s possible to augment them to get some of these features. [Tommy’s] project shows you one way to make a silk purse from a sow’s ear, at least as it relates to oscilloscopes.

Most of the problem with these lower-cost tools is their low precision due to fewer bits of analog-digital conversion. They also tend to be quite noisy, further lowering the quality of the oscilloscope. [Tommy] is focusing his efforts on the DSO138-mini, an oscilloscope with a bandwidth of 100 kHz and an effective resolution of 10 bits. The first step is to add an anti-aliasing filter to the input, which is essentially a low-pass filter that removes high frequency components of the signal, which could cause a problem due to the lower resolution of the device. After that, digital post-processing is done on the output, which removes noise caused by the system’s power supply, among other things, and essentially acts as a second low-pass filter.

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Building A Custom Zynq-7000 SoC Development Board From The Ground Up

April 20, 2025 by John Elliot V 2 Comments

In this series of 23 YouTube videos [Rich] puts the AMD Zynq-7000 SoC through its paces by building a development board from the ground up to host it along with its peripherals. The Zynq is part FPGA and part CPU, and while it has been around for a while, we don’t see nearly as many projects about it as we’d like.

[Rich] covers everything from the power system to HDMI, USB, DDR RAM, and everything in between. By the end, he’s able to boot PetaLinux.

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