Engineering

594 Articles

Remotely Interesting: Stream Gages

May 28, 2025 by 32 Comments

Near my childhood home was a small river. It wasn’t much more than a creek at the best of times, and in dry summers it would sometimes almost dry up completely. But snowmelt revived it each Spring, and the remains of tropical storms in late Summer and early Fall often transformed it into a raging torrent if only briefly before the flood waters receded and the river returned to its lazy ways.

Other than to those of us who used it as a playground, the river seemed of little consequence. But it did matter enough that a mile or so downstream was some sort of instrumentation, obviously meant to monitor the river. It was — and still is — visible from the road, a tall corrugated pipe standing next to the river, topped with a box bearing the logo of the US Geological Survey. On occasion, someone would visit and open the box to do mysterious things, which suggested the river was interesting beyond our fishing and adventuring needs.

Although I learned quite early that this device was a streamgage, and that it was part of a large network of monitoring instruments the USGS used to monitor the nation’s waterways, it wasn’t until quite recently — OK, this week — that I learned how streamgages work, or how extensive the network is. A lot of effort goes into installing and maintaining this far-flung network, and it’s worth looking at how these instruments work and their impact on everyday life.

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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.

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A Brief History Of Fuel Cells

May 22, 2025 by 15 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.

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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.”

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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.

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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.

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