Electrostatic Puck: Making An Electret

December 1, 2024 by Danie Conradie 24 Comments

You might have heard of electrets being used in microphones, but do you know what they are? Electrets produce a semi-permanent static electric field, similar to how a magnet produces a magnetic field. The ones in microphones are very small, but in the video after the break [Jay Bowles] from Plasma Channel makes a big electret and demonstrates it’s effects.

Electrets have been around since the 1800s, and are usually produced by melting an insulating material and letting it solidify between two high-voltage electrodes. The original recipe used a mix of Carnauba wax, beeswax, and rosin, which is what [Jay] tried first. He built a simple electric field detector, which is just a battery, LED and FET, with an open-ended resistor on the FET’s gate.

[Jay] 3D printed a simple cylindrical mold and stuck aluminum foil to the outer surfaces to act as the electrodes. He used his custom 6000:1 voltage transformer to hold the electrodes at ~40 kV. The first attempt did not produce a working electret because the electrodes were not in contact with the wax, and kept arcing across, which causes the electric charge to drop off. Moving the aluminum electrodes the inner surfaces of the mold eventually produced an electret detectable out to 10 inches.

This was with the original wax recipe, but there are now much better materials available, like polyethylene. [Jay] heated a a block of it in the oven until it turned into a clear blob, and compressed it in a new mold with improved insulation. This produced significantly better results, with an electric field detectable out to 24 inches.

[Jay] also built an array of detectors in a 5×5 grid, which he used to help him visualize the size and shape of the field. He once pulled off a similar trick using a grid of neon bulbs.

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Flyback, Done Right

November 24, 2024 by Jenny List 6 Comments

A common part used to create a high voltage is a CRT flyback transformer, having been a ubiquitous junk pile component. So many attempts to use them rely on brute force, with power transistors in simple feedback oscillators dropping high currents into hand-wound primaries, so it’s refreshing to see a much more nuanced approach from [Alex Lungu]. His flyback driver board drives the transformer as it’s meant to be used, in flyback mode relying on the sudden collapse of a magnetic field to generate an output voltage pulse rather than simply trying to create as much field as possible. It’s thus far more efficient than all those free running oscillators.

On the PCB is a UC3844 switch mode power supply controller driving the transformer at about 25 kHz through an IGBT. We’d be curious to know how closely the spec of the transformer is tied to the around 15 kHz it would have been run at in a typical TV, and thus what frequency would be the most efficient for it. The result as far as we can see it a stable and adjustable high voltage source with out all the high-current and over heating, something of which we approve.

Need to understand more about free running versus flyback? Read on.

‘Upgrading’ A Microwave Oven To 20 KW

October 25, 2024 by Dave Rowntree 38 Comments

Whilst microwave plasmas are nothing new around here, we were curious to see what happens at 20x the power, and since YouTuber [Styropyro] had put out a new video, we couldn’t resist seeing where this was going. Clearly, as your bog standard microwave oven can only handle at most one kilowatt; the ‘oven’ needed a bit of an upgrade.

A 16 kW water-cooled magnetron. Why not over-drive it to 20 kW for fun?

Getting hold of bigger magnetrons is tricky, but as luck — or perhaps fate — would have it, a 16 kW, water-cooled beast became available on eBay thanks to a tip from a Discord user. It was odd but perhaps not surprising that this Hitatch H0915 magnetron was being sold as a ‘heat exchanger.’

[Styropyro] doesn’t go into much detail on how to supply the anode with its specified 16 kW at 9.5 kVDC, but the usual sketchy (well down-right terrifying) transformers in the background indicate that he had just what was needed kicking around the ‘shop. Obviously, since this is a [Styropyro] video, these sorts of practical things have been discussed before, so there is no need to waste precious time and get right on to blowing stuff up!

Some classic microwave tricks are shown, like boiling water in five seconds, cooking pickles (they really do scream at 20 kW) and the grape-induced plasma-in-a-jar. It was quite clear that at this power level, containing that angry-looking plasma was quite a challenge. If it was permitted to leak out for only a few seconds, it destroyed the mica waveguide cover and risked coupling into the magnetron and frying it. Many experiments followed, a lot of which seemed to involve the production of toxic brown-colored nitrogen dioxide fumes. It was definitely good to see him wearing a respirator for this reason alone!

Is it purple or is it indigo? Beauty is in the eye of the beholder!

The main star of the demonstration was the plasma-induced emissions of various metal elements, with the rare indigo and violet colors making an appearance once the right blend of materials was introduced into the glassware. Talking of glassware, we reckon he got through a whole kitchen’s worth. We lost count of the number of exploded beakers and smashed plates. Anyway, plasma science is fun science, but obviously, please don’t try any of this at home!

For those who didn’t take an ‘electron devices’ course at college, here’s a quick guide to how magnetrons work. Plasma physics is weird; here’s how the plasma grape experiment works. Finally, this old hack is a truly terrible idea. Really don’t do this.

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Pushing The Plasma Limits With A Custom Flyback Transformer

October 22, 2024 by Danie Conradie 18 Comments

For serious high-voltage plasma, you need a serious transformer. [Jay Bowles] from Plasma Channel is taking his projects to the next level, so he built a beefy 6000:1 flyback transformer.

[Jay] first built a driving circuit for his dream transformer, starting with a simple 555 circuit and three MOSFETs in parallel to handle 90 A of current. This led to an unexpected lesson on the necessity for transistor matching as one of them let out the Magic Smoke. On his second attempt, the 555 was swapped for an adjustable pulse generator module with a display, and a single 40 A MOSFET on the output.

The transformer is built around a large 98×130 mm ferrite core, with eleven turns on the primary side. All the hard work is on the secondary side, where [Jay] designed a former to accommodate three winding sections in series. With the help of the [3D Printing Nerd], he printed PLA and resin versions but settled on the resin since it likely provided better isolation.

[Jay] spent six hours of quality time with a drill, winding 4000 feet (~1200 m) of enameled wire. On the initial test of the transformer, he got inch-long arcs on just 6 V and 15 W of input power. Before pushing the transformer to its full potential, he potted the secondary side in epoxy to reduce the chances of shorts between the windings.

Unfortunately, the vacuum chamber hadn’t removed enough of the air during potting, which caused a complete short of the middle winding as the input started pushing 11 V. This turned the transformer into a beautiful copper and epoxy paperweight, forcing [Jay] to start again from scratch.

On the following attempt [Jay] took his time during the potting process, and added sharp adjustable electrodes to act as voltage limiters on the output. The result is beautiful 2.25-inch plasma arcs on only 11 V and 100 W input power. This also meant he could power it with a single 580 mAh 3S LiPo for power.

[Jay] plans to use his new transformer to test materials he intends to use in future plasma ball, ion thruster, and rail gun projects. We’ll be keeping an eye out for those!

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Secret Messages On Plastic, Just Add Tesla Coil

August 1, 2024 by Donald Papp 15 Comments

Here’s a short research paper from 2013 that explains how to create “hydroglyphics”, or writing with selecting surface wetting. In it, an apparently normal-looking petri dish is treated so as to reveal a message when wetted with water vapor. The contrast between hydrophobic and hydrophilic surfaces, which is not visible to the naked eye, becomes visible when misted with water. All it took was a mask, and a little treatment with a modified Tesla coil.

Plastics tend to be hydrophobic, meaning their surface repels water. These plastics also tend to be non-receptive to things like inks and adhesives. However, there is an industrial process called corona treatment (invented by Verner Eisby in 1951) that changes the surface energy of materials like plastics, rendering them more receptive to inks, coatings, and adhesives. Eisby’s company Vetaphone still exists today, and has a page describing the process.

What’s this got to do with the petri dishes and their secret messages? The process is essentially the same. By using a Tesla coil modified with a metal wire mesh, the surface of the petri dish is exposed to the coil’s discharge, altering its surface energy and rendering it hydrophilic. By selectively blocking the discharge with a nonconductive mask made from a foam sticker, the masked area remains hydrophobic. Mist the surface with water, and the design becomes visible.

The effects of corona treatment decay over time, but we think this is exactly the sort of thing that is worth keeping in mind just in case it ever comes in useful. Compact Tesla coils are fairly easy to get a hold of nowadays, but it’s also possible to make your own.

Cheap Musical Tesla Coil Put Through Its Paces

May 1, 2024 by Lewin Day 4 Comments

Once upon a time, musical Tesla coils were something you primarily saw at high-voltage hobby meets. They’ve become more popular in recent years, and now you can even buy cheap examples online. [mircemk] decided to buy one and gave it a whirl.

The device comes with a power supply capable of delivering 2 amps at 48 V. It’s a solid-state design, relying on SMD MOSFETs to generate high-voltage, high-frequency output that makes the sparks we all know and love. The pancake coil is key to the design, and is made using a trace on the PCB — a neat technique compared to making one with a laborious winding operation.

The coil can be used to simply generate sparks, or it can be modulated musically. In this mode of operation, it’s intended to be driven by square wave audio for simplicity’s sake. As seen in [mircemk]’s video, the sound quality is pretty decent for a cheap device, and the Super Mario theme is readily recognizable. As a guide, he also demonstrates how to drive the device using an Arduino set up for square wave audio output.

If you prefer to build your own singing Tesla coil, you can go that route instead. Or, you could buy one of these and hack it, and drop us a line with what you come up with! Similar devices are all over the ‘net. Continue reading “Cheap Musical Tesla Coil Put Through Its Paces” →

High-Voltage Fun With An Inexpensive Power Supply

March 14, 2024 by Dan Maloney 25 Comments

It used to be that nearly every home had at least one decent high-voltage power supply. Of course, it was dedicated to accelerating electrons and slamming them into phosphors so we could bathe ourselves in X-rays (not really) while watching Howdy Doody. These days the trusty tube has been replaced with LEDs and liquid crystals, which is a shame because there’s so much fun to be had with tens of thousands of volts at your disposal.

That’s the impetus behind this inexpensive high-voltage power supply by [Sebastian] over at Baltic Labs. The heavy lifting for this build is done by a commercially available power supply for a 50-watt CO₂ laser tube, manufactured — or at least branded — by VEVOR, a company that seems intent on becoming the “Harbor Freight of everything.” It’s a bold choice given the brand’s somewhat questionable reputation for quality, but the build quality on the supply seems decent, at least from the outside. [Sebastian] mounted the supply inside a rack-mount case, as one does, and provided some basic controls, including the obligatory scary-looking toggle switch with safety cover. A pair of ammeters show current and voltage, the latter with the help of a high-voltage resistor rated at 1 gigaohm (!). The high-voltage feedthrough on the front panel is a little dodgy — a simple rubber grommet — but along with the insulation on the high-voltage output lead, it seems to be enough.

The power supply’s 30 kV output is plenty for [Sebastian]’s current needs, which from the video below appear to mainly include spark gap experiments. He does mention that 50 kV commercial supplies are available too, but it would be tough to do that for the $150 or so he spent on this one. There are other ways to go, of course — [Niklas] over at Advanced Tinkering recently shared his design for a more scratch-built high-voltage supply that’s pretty cool too. Whatever you do, though, be careful; we’ve been bitten by a 50 kV flyback supply before and it’s no joke.

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