Defective 3D Printing For Great Strength

February 2, 2022 by 6 Comments

Most of us want our 3D prints to be perfect. But at Cornell University, they’ve been experimenting with deliberately introducing defects into printed titanium. Why? Because using a post-print treatment of heat and pressure they can turn those defects into assets, leading to a stronger and more ductile printed part.

The most common ways to print metal use powders melted together, and these lead to tiny pores in the material that weaken the final product. Using Ti-6Al-4V, the researchers deliberately made a poor print that had more than the usual amount of defects. Then they applied extreme heat and pressure to the resulting piece. The pressure caused the pores to close up, and changed the material’s internal structure to be more like a composite.

Reports are that the pieces treated in this way have superior properties to parts made by casting and forging, much less 3D printed parts. In addition, the printing process usually creates parts that are stronger in some directions than others. The post processing breaks that directionality and the finished parts have equal strength in all directions.

The hot isostatic pressing (HIP) process isn’t new — it is commonly used in metal and ceramic processing — so this method shouldn’t require anything more exotic than that. Granted, even cheap presses from China start around $7,000 and go way up from there, but if you are 3D printing titanium, that might not be such a big expenditure. The only downside seems to be that if the process leaves any defects partially processed, it can lead to fatigue failures later.

We wonder if this development will impact all the car parts being printed in titanium lately. If you need something to print in titanium, consider hacking your rib cage.

Know Audio: A Mess Of Cables

February 2, 2022 by 101 Comments

We’ve now spent several months in this series journeying through the world of audio, and along the way we’ve looked at the various parts of a Hi-Fi system from the speaker backwards to the source. It’s been an enjoyable ride full of technical detail and examining Hi-Fi myths in equal measure, but now it’s time to descend into one of the simplest yet most controversial areas of audio reproduction. Every audio component, whether digital or analogue, must be connected into whatever system it is part of, and this is the job of audio cables, sometimes referred to as interconnects. They are probably the single component most susceptible to tenuous claims about their performance, with audiophiles prepared to spend vast sums on cables claimed to deliver that extra bit of listening performance. Is there something in it, or are they all the same bits of wire with the expensive ones being a scam? Time to take a look.

What Makes A Nearly Good Cable

In a typical domestic audio system with digital and analogue signals you might expect to find two types of cable, electrical interconnects that could carry either analogue or digital signals, and optical ones for digital signals. We’re here to talk about the electrical cables here as they’re the ones used for analogue signals, so lets start with a little transmission line theory. Continue reading “Know Audio: A Mess Of Cables” →

Hackaday Invades The FLOSS Weekly Podcast

February 2, 2022 by No comments

Regular Hackaday readers will know that we’re big supporters of free/libre and open source software (FLOSS) around these parts. There’s an excellent chance you are too, as so many of the incredible projects you send our way make it a habit to share their innermost details, from firmware source code to the OpenSCAD files that generate its 3D printed components. So when our recently minted Editor in Chief [Elliot Williams] was invited to join This Week in Tech’s FLOSS Weekly podcast, he jumped at the chance to represent our little corner of the Internet to the wider world of open source aficionados. (Ed: The final version is now live!  How did we get episode 666?!)

Hosted by [Doc Searls], FLOSS Weekly is known for its in-depth interviews with “the most interesting and important people in the Open Source and Free Software community”, so we hope the incursion by hacker rabble such as ourselves doesn’t taint their brand too much.

It’s live streamed every Wednesday at 12:30 PM Eastern / 9:30 AM Pacific / 17:30 UTC, which means that by the time this post hits the main page of the site, you’ve still got time to tune in. For those of you with gainful employment who can’t slack off for an hour or so in the middle of the workweek, the recorded version will be available afterwards for your time-shifted viewing and or listening pleasure.

[Elliot] will be joined by Hackaday writer and regular co-host of FLOSS Weekly [Jonathan Bennett], making this something of a Jolly Wrencher double-feature. [Jonathan] has been providing readers with a regular peek into the other type of hacking with his fantastic This Week in Security column, and is himself a devout FOSS supporter with a particular passion for GNU/Linux. We’re excited to listen in as the trio riffs on open source at the crossroads of hardware and software, not just because it promises to be an entertaining bit of programming, but because it’s a great opportunity to introduce the world of Hackaday to the wider open source audience.

Underwater Tanks Turn Energy Storage Upside-Down

February 2, 2022 by 129 Comments

Pumped hydro storage is one of the oldest grid storage technologies, and one of the most widely deployed, too. The concept is simple – use excess energy to pump a lot of water up high, then run it back through a turbine when you want to get the energy back later.

With the rise in renewable energy deployments around the world, there is much interest in finding ways to store energy from these often-intermittent sources. Traditional pumped hydro can help, but there is only so much suitable land to work with.

However, there could be a solution, and it lurks deep under the waves. Yes, we’re talking about underwater pumped hydro storage!

Continue reading “Underwater Tanks Turn Energy Storage Upside-Down” →

Building Forged Carbon Fiber Wings For Radio Control Cars

February 2, 2022 by 6 Comments

When it comes to building decent aerodynamic devices, you want to focus on getting your geometry accurate, and making sure your parts are strong enough to deal with the force they’re generating. This build from [Engineering After Hours] delivers on those fronts, consisting of a high-downforce wing for a small RC car.

The video points out that, at best, even a decent RC car will have pretty crappy aerodynamic parts from the factory, with a lift-to-drag (L/D)ratio of 2-3:1 at best. This means that, while they may create some small amount of downforce, they’re also creating plenty of drag at the same time.

The dual-element wing designed here is much more efficient, hitting an L/D ratio in the vicinity of 17:1 – a huge improvement. Even a casual eye can note that the design looks a lot more like something you’d see on a full-size car, versus some of the whackier designs seen on toys.

The wing is built with a forged carbon fiber process using 3D-printed molds, to give the wing plenty of strength. Given that it’s built for an RC car that can do over 100 mph, making sure the wing is stiff enough to perform at speed is key.

[Engineering After Hours] does a great job of showing how to prepare the molds, fill them with carbon fiber, and pour the resin, and discusses plenty of useful tips on how to achieve good results with the forged carbon process.

The result is an incredibly impressive rear wing with aerodynamic performance to match its good looks. It may be more complicated than 3D printing, but the results of the work are that much tougher.

We’ve seen other aero experiments from [Engineering After Hours] before, too. Video after the break.

Continue reading “Building Forged Carbon Fiber Wings For Radio Control Cars” →

A Portable Projecting Pi For Education

February 2, 2022 by 16 Comments

We cover a lot of cyberdeck projects here at Hackaday, custom portable computers often built around the Raspberry Pi. It’s not often that we cover a computer that perfectly achieves and exceeds what a cyberdeck is trying to do without being a cyberdeck in any way, but that’s what [Subir Bhaduri] has done. In addressing the need for Indian schoolchildren to catch up on two years of COVID-disrupted schooling he’s created the pπ, a Raspberry Pi, projector, and keyboard all-in-one computer in a neat sheet-metal case that looks as though it might be just another set of spanners or similar. At a stroke he’s effortlessly achieved the ultimate cyberdeck, because this machine is no sci-fi prop, instead it has a defined use which it fulfills admirably.

All the files to build your own can be found in a GitLab repository. The case is laser-cut sheet metal, and he’s put in a cost breakdown which comes out at a relatively healthy 17200 Indian rupees, or around 230 US dollars. We hope that it serves its purpose well and provides a rugged and reliable teaching aid for a generation from whom COVID has taken so much. You can see more in the video below the break.

Continue reading “A Portable Projecting Pi For Education” →

Linux Arcade Cab Gives Up Its Secrets Too Easily

February 1, 2022 by 9 Comments

Sometimes reverse engineering embedded systems can be a right old faff, with you needing to resort to all kinds of tricks such as power glitching in order to poke a tiny hole in the armour, giving you an way in. And, sometimes the door is just plain wide open. This detailed exploration of an off-the-shelf retro arcade machine, is definitely in that second camp, for an unknown reason. [Matthew Alt] of VoidStar Security, took a detailed look into how this unit works, which reads as a great introduction to how embedded Linux is constructed on these minimal systems.

Could this debug serial port be more obvious?

The hardware is the usual bartop cabinet, with dual controls and an LCD display, with just enough inside a metal enclosure to drive the show. Inside this, the main PCB has the expected minimal ARM-based application processor with its supporting circuit. The processor is the Rockchip RK3128, sporting a quad-core ARM Neon and a Mali400 GPU, but the main selling point is the excellent Linux support. You’ll likely see this chip or its relatives powering cheap Android TV boxes, and it’s the core of this nice looking ‘mini PC’ platform from firefly. Maybe something to consider seeing as though Raspberry Pis are currently so hard to come by?

Anyway, we digress a little, [Matthew] breaks it down for us in a very methodical way, first by identifying the main ICs and downloading the appropriate datasheets. Next he moves on to connectors, locating an internal non-user-facing USB micro port, which is definitely going to be of interest. Finally, the rather obvious un-populated 3-pin header is clearly identified as a serial port. This was captured using a Saleae clone, to verify it indeed was a UART interface and measure the baud rate. After doing that, he hooked it into a Raspberry Pi UART and by attaching the standard screen utility to the serial device, lo-and-behold, a boot log and a root prompt! This thing really is barn-door wide-open.

Is that a root prompt you have for me? Oh why yes it is!

Simply by plugging in a USB stick, the entire flash memory was copied over, partitions and all, giving a full backup in case subsequent hacking messed things up. Being based on U-Boot, it was a trivial matter of just keying in ‘Ctrl-C’ at boot time, and he was dropped straight into the U-Boot command line, and all configuration could be easily read out. By using U-Boot to low-level dump the SPI flash to an external USB device, via a RAM copy, he proved he could do the reverse and write the same image back to flash without breaking something, so it was now possible to reverse engineer the software, make changes and write it back. Automation of the process was done using Depthcharge on the Raspberry Pi, which was also good to read about. We will keep an eye on the blog for what he does with it next!

As we’ve covered earlier, embedded Linux really is everywhere, and once you’ve got hardware access and some software support, hacking in new tricks is not so hard either.