Big Chemistry: Hydrofluoric Acid

For all of the semiconductor industry’s legendary reputation for cleanliness, the actual processes that go into making chips use some of the nastiest stuff imaginable. Silicon oxide is comes from nothing but boring old sand, and once it’s turned into ultrapure crystals and sliced into wafers, it still doesn’t do much. Making it into working circuits requires dopants like phosphorous and boron to give the silicon the proper semiconductor properties. But even then, a doped wafer doesn’t do much until an insulating layer of silicon dioxide is added and the unwanted bits are etched away. That’s a tall order, though; silicon dioxide is notoriously tough stuff, largely unreactive and therefore resistant to most chemicals. Only one substance will do the job: hydrofluoric acid, or HFA.

HFA has a bad reputation, and deservedly so, notwithstanding its somewhat overwrought treatment by Hollywood. It’s corrosive to just about everything, it’s extremely toxic, and if enough of it gets on your skin it’ll kill you slowly and leave you in agony the entire time. But it’s also absolutely necessary to make everything from pharmaceuticals to cookware, and it takes some big chemistry to do it safely and cheaply.

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Electrical Steel: The Material At The Heart Of The Grid

When thoughts turn to the modernization and decarbonization of our transportation infrastructure, one imagines it to be dominated by exotic materials. EV motors and wind turbine generators need magnets made with rare earth metals (which turn out to be not all that rare), batteries for cars and grid storage need lithium and cobalt, and of course an abundance of extremely pure silicon is needed to provide the computational power that makes everything work. Throw in healthy pinches of graphene, carbon fiber composites and ceramics, and minerals like molybdenum, and the recipe starts looking pretty exotic.

As necessary as they are, all these exotic materials are worthless without a foundation of more familiar materials, ones that humans have been extracting and exploiting for eons. Mine all the neodymium you want, but without materials like copper for motor and generator windings, your EV is going nowhere and wind turbines are just big lawn ornaments. But just as important is iron, specifically as the alloy steel, which not only forms the structural elements of nearly everything mechanical but also appears in the stators and rotors of motors and generators, as well as the cores of the giant transformers that the electrical grid is built from.

Not just any steel will do for electrical use, though; special formulations, collectively known as electrical steel, are needed to build these electromagnetic devices. Electrical steel is simple in concept but complex in detail, and has become absolutely vital to the functioning of modern society. So it pays to take a look at what electrical steel is and how it works, and why we’re going nowhere without it.

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Sprint: The Mach 10 Magic Missile That Wasn’t Magic Enough

Defending an area against incoming missiles is a difficult task. Missiles are incredibly fast and present a small target. Assuming you know they’re coming, you have to be able to track them accurately if you’re to have any hope of stopping them. Then, you need some kind of wonderous missile of your own that’s fast enough and maneuverable enough to take them out.

It’s a task that at times can seem overwhelmingly impossible. And yet, the devastating consequences of a potential nuclear attack are so great that the US military had a red hot go anyway. In the 1970s, America’s best attempt to thwart incoming Soviet ICBMs led to the development of the Sprint ABM—a missile made up entirely of improbable numbers.

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How Airplanes Mostly Stopped Flying Into Terrain And Other Safety Improvements

We have all heard the statistics on how safe air travel is, with more people dying and getting injured on their way to and from the airport than while traveling by airplane. Things weren’t always this way, of course. Throughout the early days of commercial air travel and well into the 1980s there were many crashes that served as harsh lessons on basic air safety. The most tragic ones are probably those with a human cause, whether it was due to improper maintenance or pilot error, as we generally assume that we have a human element in the chain of events explicitly to prevent tragedies like these.

Among the worst pilot errors we find the phenomenon of controlled flight into terrain (CFIT), which usually sees the pilot losing track of his bearings due to a variety of reasons before a usually high-speed and fatal crash. When it comes to keeping airplanes off the ground until they’re at their destination, here ground proximity warning systems (GPWS) and successors have added a layer of safety, along with stall warnings and other automatic warning signals provided by the avionics.

With the recent passing of C. Donald Bateman – who has been credited with designing the GPWS – it seems like a good time to appreciate the technology that makes flying into the relatively safe experience that it is today.

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Keeping Watch Over The Oceans With Data Buoys

When viewed from just the right position in space, you’d be hard-pressed to think that our home planet is anything but a water world. And in all the ways that count, you’d be right; there’s almost nothing that goes on on dry land that isn’t influenced by the oceans. No matter how far you are away from an ocean, what’s going on there really matters.

But how do we know what’s going on out there? The oceans are trackless voids, after all, and are deeply inhospitable to land mammals such as us. They also have a well-deserved reputation for eating anything that ventures into them at the wrong time and without the proper degree of seafarer’s luck, and they also tend to be places where the resources that run our modern technological society are in short supply.

Gathering data about the oceans is neither cheap nor easy, but it’s critically important to everything from predicting what the weather will be next week to understanding the big picture of what’s going on with the climate. And that requires a fleet of data buoys, outnumbering the largest of the world’s navies and operating around the clock, keeping track of wind, weather, and currents for us.

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How Do You Test If An EEPROM Can Hold Data For 100 Years?

Data retention is a funny thing. Atmel will gladly tell you that the flash memory in an ATmega32A will retain its data for 100 years at room temperature. Microchip says its EEPROMs will retain data for over 200 years. And yet, humanity has barely had a good grasp on electricity for that long. Heck, the silicon chip itself was only invented in 1958. EEPROMs and flash storage are altogether younger themselves.

How can these manufacturers make such wild claims when there’s no way they could have tested their parts for such long periods of time? Are they just betting on the fact you won’t be around to chastise them in 2216 when your project suddenly fails due to bit rot.

Well, actually, there’s a very scientific answer. Enter the practice of accelerated wear testing.

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Parachute Drops Are Still A Viable Solution For Data Recovery From High Altitude Missions

Once upon a time, when the earliest spy satellites were developed, there wasn’t an easy way to send high-quality image data over the air. The satellites would capture images on film and dump out cartridges back to earth with parachutes that would be recovered by military planes.

It all sounds so archaic, so Rube Goldberg, so 1957. And yet, it’s still a viable method for recovering big globs of data from high altitude missions today. Really, you ask? Oh, yes indeed—why, NASA’s gotten back into the habit just recently!

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