Ultrasonic soldering is a little-known technology that allows soldering together a variety of metals and ceramics that would not normally be possible. It requires a special ultrasonic soldering iron and solder that is not cheap or easy to get hold of, so [Ben Krasnow] of [Applied Science] made his own.
Ultrasonic soldering irons heat up like standard irons, but also require an ultrasonic transducer to create bonds to certain surfaces. [Ben] built one by silver soldering a piece of stainless steel rod (as a heat break) between the element of a standard iron and a transducer from an ultrasonic cleaner. He made his special active solder by melting all the ingredients in his vacuum induction furnace. It is similar to lead-free solder, but also contains titanium and small amounts of cerium and gallium. In the video below [Ben] goes into the working details of the technology and does some practical experimentation with various materials.
Ultrasonic soldering is used mainly for electrically bonding metals where clamping is not possible or convenient. The results are also not as neat and clean as with standard solder. We covered another DIY ultrasonic soldering iron before, but it doesn’t look like that one ever did any soldering.
Ultrasonic energy has several interesting mechanical applications that we’ve covered in the past, including ultrasonic cutting and ultrasonic welding.
For most of human history, there was no such thing as a professional scientist. Those who dabbled in “natural philosophy” were mainly men — and occasionally women — of privilege and means, given to spend their time looking into the workings of the world. Most went where their interest lay, exploring this facet of geology or that aspect of astronomy, often combining disciplines or switching to new ones as they felt like it. They had the freedom to explore the universe without the pressure to “publish or perish,” and yet they still often managed to pull back the curtain of ignorance and superstition that veiled the world for eons, at least somewhat.
In their footsteps follow today’s citizen scientists, a relatively small cohort compared to the great numbers of professional scientists that universities churn out year after year. But where these credentialed practitioners are often hyper-focused on a particular sub-field in a highly specialized discipline, the citizen scientist enjoys more freedom to explore the universe, as his or her natural philosopher forebears did. These citizen scientists — many of whom are also traditionally credentialed — are doing important work, and some are even publishing their findings in mainstream journals. Continue reading “Citizen Science Hack Chat With Ben Krasnow”→
[Ben] takes apart those rectangular plastic security tags that end up embarrassing everyone when the sales people forget to demagnetize them before you leave the store. Inside are two metal strips. One strip gets magnetized and demagnetized, and the other is magnetostrictive — meaning it changes length ever so slightly in the presence of a magnetic field.
A sender coil hits the magnetostrictive strip with a pulsed signal at the strip’s resonant frequency, around 58kHz. The strip expands and contracts along with the sender’s magnetic field. When the sender’s pulse stops, the strip keeps vibrating for a tiny bit of time, emitting an AC magnetic field that’s picked up by the detector. You’re busted.
The final wrinkle is the magnetizable metal strip inside the tag. When it’s not magnetized at all, or magnetized too strongly, the magnetostrictive strip doesn’t respond as much to the sender’s field. When the bias magnet is magnetized just right, the other strip rings like it’s supposed to. Which is why they “demagnetize” the strips at checkout.
We haven’t even spoiled [Ben]’s explanation. He does an amazing job of investigating all of this. He even measures these small strips changing their length by ten parts per million. It’s a great bit of low-tech measurement that ends up being right on the money and deserves the top spot in your “to watch” list.
And now that magenetostriction is in our collective unconscious, what’s the next place we’ll see it pop up?
When you’ve got a scanning electron microscope sitting around, you’re going to find ways to push the awesome envelope. [Ben Krasnow] is upping his SEM game with a new rig to improve image capture (video link) and more easily create animated GIFs and videos.
The color scheme of the SEM housing gives away its 80s vintage, and the height of image capture technology back then was a Polaroid camera mounted over the instrument’s CRT. No other video output was provided, so [Ben] dug into the blueprints and probed around till he found the high-resolution slow scan signal.
To make his Teensy-LC happy, he used a few op-amps to condition the analog signal for the greatest resolution and split out the digital sync signals, which he fed into the analog and digital ports respectively. [Ben] then goes into a great deal of useful detail on how he got the video data encoded and sent over USB for frame capture and GIF generation. Reading the ADC quickly without jitter and balancing data collection with transmission were tricky, but he has established a rock-solid system for it.
Hackaday Prize judge [Ben Krasnow] has been busy lately. He’s put his scanning electron microscope (SEM) to work creating an animation of a phonograph needle playing a record. (YouTube link) This is the same 80’s SEM [Ben] hacked back in November. Unfortunately, [Ben’s] JSM-T200 isn’t quite large enough to hold an entire 12″ LP, so he had to cut a small section of a record out. The vinyl mods weren’t done there though. SEMs need a conductive surface for imaging. Vinyl is an insulator. [Ben] dealt with this by using his vacuum chamber to evaporate a thin layer of silver on the vinyl.
Just imaging the record wouldn’t be enough; [Ben] wanted an animation of a needle traveling through the record grove. He tore apart an old phonograph needle and installed it in on a copper wire in the SEM. Thanks to the dual stage setup of the JSM-T200, [Ben] was able to move the record-chip and needle independently. He could then move the record underneath the needle as if it were actually playing. [Ben] used his oscilloscope to record 60 frames, each spaced 50 microns apart. He used octave to process the data, and wound up with the awesome GIF animation you see on the left.
[Ben] wasn’t done though. He checked out a few other recording formats, including CD and DVD optical media, and capacitance electronic disc, an obscure format from RCA which failed miserably in the market. The toughest challenge [Ben] faced was imaging the CD media. The familiar pits of a CD are stored on a thin aluminum layer sandwiched between the lacquer label and the plastic disc. He tried dissolving the plastic with chemicals, but enough plastic was left behind to distort the image. The solution turned out to be double-sided tape. Sticking some tape down on the CD and peeling it off cleanly removed the aluminum, and provided a sturdy substrate with which to mount the sample in the SEM.
One of the first problems every new hacker/maker must solve is this: What’s the best way to attach part “A” to part “B”. We all have our go-to solutions. Hot glue, duck tape ( “duct tape” if you prefer) or maybe even zip ties. Super glue, epoxy, and if we’re feeling extra MacGyver-ish then it’s time for some bubble gum. For some Hackaday readers, this stuff will seem like old hat, but for a beginner it can be a source of much frustration. Even well versed hackers might pick up a few handy tips and tricks presented in this video after the break.
In part one of this series, [Ben Krasnow] shows us the proper use of just a few of the tools and techniques he uses in his shop. [Ben] starts out with a zip-tie tool which he loves in part because of a tension setting that ensures it’s tight but not overly. He moves on to advice for adhesive-vs-material and some tips on using threaded fasteners in several different circumstances. He also included a list of the parts and tools he uses so you don’t have to go hunting them down.
On Thursday night Hackaday hosted an event in San Francisco to commemorate the launch of the 2014 Hackaday Omnibus. Our first print edition, compiled to commemorate some of the finest original content which we published last year should begin shipping as early as today. To celebrate the occasion, we were graced by a full house of amazing guests. Is it lame to say some of the people I respect most in the world were there?
Whenever you get a lot of people together, a good rule of thumb is to seize the opportunity to have them speak about what they’re doing. It’s not a big “ask” either; 8-minutes on what you’re passionate about is pretty simple.
[Jonathan Foote] gave a talk on generating RGBY colors from Hue. The project is ongoing but explores the concept of mixing colors of light with one additional source added to traditional red, green, and blue. [Priya Kuber] recently moved to San Francisco. She recently concluded more than a year of standing up the Arduino office in India (relevant but unrelated video). Her talk covered the emerging maker/hacker hardware scene in India which is showing amazing growth. [Chris McCoy] demonstrated his Raver Rings which began a Kickstarter on the same day. [Elecia White] of embedded.fm spoke about the educational opportunities that podcasts and other delivery medium provide and the responsibility we all have to guide our continued learning. [Emile Petrone] talked about an upcoming feature for his site Tindie which will add manufacturer information and ratings to the mix. And rounding things out [Dave Grossman] gave a talk on his Virtual Carl project which used video footage of his grandfather, combined with a Raspberry Pi and peripherals to create a remembrance of the man in virtual form.
He also showed off a lens that can be focused electronically. This is not mechanical, there are zero moving parts. Instead a droplet of oil floating in water is the lens. A 75V, AC power supply pulls on the droplet, altering the meniscus to focus the lens. He didn’t fabricate the device from scratch, but the concept is completely new to us and quite interesting.
Othermill is located in the SF area. They produce a desktop milling machine which is spectacular at routing PCBs. The little wonder isn’t limited to that though. Above you can see [Brian] holding up a milled wooden plaque which has milled mother-of-pearl inlays. The table is also strewn with other examples in wax, metal, wood, and more.
The rest of the evening was devoted to conversation on all topics. Get enough hardware geeks in one room and they’ll solve the world’s problems, right? That’s a conversation for another post.
Couldn’t make it to this one but still in the San Francisco area at least occasionally? We held this at the Supplyframe office. They host a ton of great events like the Hardware Developers Didactic Galactic.