Engineering

572 Articles

EMF Forming Was A Neat Aerospace Breakthrough

May 23, 2025 by 9 Comments

Typically, when we think about forming metal parts, we think about beating them with hammers, or squeezing them with big hydraulic presses. But what if magnets could do the squeezing? As it turns out—Grumman Aerospace discovered they can, several decades ago! Even better, they summed up this technique in a great educational video which we’ve placed below the break.

The video concerns the development of the Grumman EMF Torque Tube. The parts are essentially tubes with gear-like fittings mounted in either end, which are fixed with electromagnetic forming techniques instead of riveting or crimping. Right away, we’re told the key benefits—torque tubes built this way are “stronger, lighter, and more fatigue resistant” than those built with conventional techniques. Grumman used these torque tubes in such famous aircraft as the F-14 Tomcat, highlighting their performance and reliability.

Continue reading “EMF Forming Was A Neat Aerospace Breakthrough” →

A Brief History Of Fuel Cells

May 22, 2025 by 13 Comments

If we asked you to think of a device that converts a chemical reaction into electricity, you’d probably say we were thinking of a battery. That’s true, but there is another device that does this that is both very similar and very different from a battery: the fuel cell.

In a very simple way, you can think of a fuel cell as a battery that consumes the chemicals it uses and allows you to replace those chemicals so that, as long as you have fuel, you can have electricity. However, the truth is a little more complicated than that. Batteries are energy storage devices. They run out when the energy stored in the chemicals runs out. In fact, many batteries can take electricity and reverse the chemical reaction, in effect recharging them. Fuel cells react chemicals to produce electricity. No fuel, no electricity.

Continue reading “A Brief History Of Fuel Cells” →

Big Chemistry: Cement And Concrete

May 7, 2025 by 24 Comments

Not too long ago, I was searching for ideas for the next installment of the “Big Chemistry” series when I found an article that discussed the world’s most-produced chemicals. It was an interesting article, right up my alley, and helpfully contained a top-ten list that I could use as a crib sheet for future articles, at least for the ones I hadn’t covered already, like the Haber-Bosch process for ammonia.

Number one on the list surprised me, though: sulfuric acid. The article stated that it was far and away the most produced chemical in the world, with 36 million tons produced every year in the United States alone, out of something like 265 million tons a year globally. It’s used in a vast number of industrial processes, and pretty much everywhere you need something cleaned or dissolved or oxidized, you’ll find sulfuric acid.

Staggering numbers, to be sure, but is it really the most produced chemical on Earth? I’d argue not by a long shot, when there’s a chemical that we make 4.4 billion tons of every year: Portland cement. It might not seem like a chemical in the traditional sense of the word, but once you get a look at what it takes to make the stuff, how finely tuned it can be for specific uses, and how when mixed with sand, gravel, and water it becomes the stuff that holds our world together, you might agree that cement and concrete fit the bill of “Big Chemistry.”

Continue reading “Big Chemistry: Cement And Concrete” →

To See Within: Detecting X-Rays

April 23, 2025 by 19 Comments

It’s amazing how quickly medical science made radiography one of its main diagnostic tools. Medicine had barely emerged from its Dark Age of bloodletting and the four humours when X-rays were discovered, and the realization that the internal structure of our bodies could cast shadows of this mysterious “X-Light” opened up diagnostic possibilities that went far beyond the educated guesswork and exploratory surgery doctors had relied on for centuries.

The problem is, X-rays are one of those things that you can’t see, feel, or smell, at least mostly; X-rays cause visible artifacts in some people’s eyes, and the pencil-thin beam of a CT scanner can create a distinct smell of ozone when it passes through the nasal cavity — ask me how I know. But to be diagnostically useful, the varying intensities created by X-rays passing through living tissue need to be translated into an image. We’ve already looked at how X-rays are produced, so now it’s time to take a look at how X-rays are detected and turned into medical miracles.

Continue reading “To See Within: Detecting X-Rays” →

Deep Drawing With Ultrasonics

March 9, 2025 by 17 Comments

Small cylindrical parts are often formed through deep drawing — a process by which a punch forms the finished piece from a flat sheet of metal using a forming die. If it sounds like that stresses the metal, it does. But researchers at Fraunhofer have found a way to reduce friction protecting both the material and the tools that do the forming. The process — known as VibroDraw — uses ultrasonic vibrations at around 500 Hz.

Researchers claim a 20% reduction in friction now, and it may be possible to go even further. With less friction, it is possible to do a deeper draw in a single stage. It also creates less heat which is good for tool life and prevents overheating lubricant. The process has a patent if you want more details. You might need to brush up on your German, though. Unsurprisingly, the vibrations are from a piezoelectric transducer.

Copper is soft enough to use 3D printed dies. We don’t know if this technique would help with that or not. Then there’s hydroforming. If you have any results using ultrasonics with these or any other techniques, be sure to let us know.

Big Chemistry: Glass

March 5, 2025 by 12 Comments

Humans have been chemically modifying their world for far longer than you might think. Long before they had the slightest idea of what was happening chemically, they were turning clay into bricks, making cement from limestone, and figuring out how to mix metals in just the right proportions to make useful new alloys like bronze. The chemical principles behind all this could wait; there was a world to build, after all.

Among these early feats of chemical happenstance was the discovery that glass could be made from simple sand. The earliest glass, likely accidentally created by a big fire on a sandy surface, probably wasn’t good for much besides decorations. It wouldn’t have taken long to realize that this stuff was fantastically useful, both as a building material and a tool, and that a pinch of this and a little of that could greatly affect its properties. The chemistry of glass has been finely tuned since those early experiments, and the process has been scaled up to incredible proportions, enough to make glass production one of the largest chemical industries in the world today.

Continue reading “Big Chemistry: Glass” →

LTA’s Pathfinder 1: The Dawn Of A New Age Of Airships?

March 4, 2025 by 32 Comments

Long before the first airplanes took to the skies, humans had already overcome gravity with the help of airships. Starting with crude hot air balloons, the 18th century saw the development of more practical dirigible airships, including hydrogen gas balloons. On 7 January 1785, French inventor, and pioneer of gas balloon flight Jean-Pierre Blanchard would cross the English Channel in such a hydrogen gas balloon, which took a mere 2.5 hours. Despite the primitive propulsion and steering options available at the time, this provided continued inspiration for new inventors.

With steam engines being too heavy and cumbersome, it wasn’t until the era of internal combustion engines a century later that airships began to develop into practical designs. Until World War 2 it seemed that airships had a bright future ahead of them, but amidst a number of accidents and the rise of practical airplanes, airships found themselves mostly reduced to the not very flashy role of advertising blimps.

Yet despite popular media having declared rigid airships such as the German Zeppelins to be dead and a figment of a historic fevered imagination, new rigid airships are being constructed today, with improvements that would set the hearts of 1930s German and American airship builders aflutter. So what is going on here? Are we about to see these floating giants darken the skies once more?

Continue reading “LTA’s Pathfinder 1: The Dawn Of A New Age Of Airships?” →