Welding Wood Is As Simple As Rubbing Two Sticks Together

July 21, 2024 by Dan Maloney 12 Comments

Can you weld wood? It seems like a silly question — if you throw a couple of pieces of oak on the welding table and whip out the TIG torch, you know nothing is going to happen. But as [Action Lab] shows us in the video below, welding wood is technically possible, if not very practical.

Since experiments like this sometimes try to stretch things a bit, it probably pays to define welding as a process that melts two materials at their interface and fuses them together as the molten material solidifies. That would seem to pose a problem for wood, which just burns when heated. But as [Action Lab] points out, it’s the volatile gases released from wood as it is heated that actually burn, and the natural polymers that are decomposed by the heat to release these gases have a glass transition temperature just like any other polymer. You just have to heat wood enough to reach that temperature without actually bursting the wood into flames.

His answer is one of the oldest technologies we have: rubbing two sticks together. By chucking a hardwood peg into a hand drill and spinning it into a slightly undersized hole in a stick of oak, he created enough heat and pressure to partially melt the polymers at the interface. When allowed to cool, the polymers fuse together, and voila! Welded wood. Cutting his welded wood along the joint reveals a thin layer of material that obviously underwent a phase change, so he dug into this phenomenon a bit and discovered research into melting and welding wood, which concludes that the melted material is primarily lignin, a phenolic biopolymer found in the cell walls of wood.

[Action Lab] follows up with an experiment where he heats bent wood in a vacuum chamber with a laser to lock the bend in place. The experiment was somewhat less convincing but got us thinking about other ways to exclude oxygen from the “weld pool,” such as flooding the area with argon. That’s exactly what’s done in TIG welding, after all. Continue reading “Welding Wood Is As Simple As Rubbing Two Sticks Together” →

Low-Cost Cryocooler Pumps Out Cheap DIY Liquid Nitrogen

July 15, 2024 by Dan Maloney 18 Comments

A word of caution if you’re planning to try this cryocooler method for making liquid nitrogen: not only does it involve toxic and flammable gasses and pressures high enough to turn the works into a bomb, but you’re likely to deplete your rent account with money you’ll shell out for all the copper tubing and fittings. You’ve been warned.

In theory, making liquid nitrogen should be as easy as getting something cold enough that nitrogen in the air condenses. The “cold enough” part is the trick, and it’s where [Hyperspace Pirate]’s cryocooler expertise comes into play. His setup uses recycled compressors from cast-off air conditioners and relies on a mixed-gas Joule-Thomson cycle. He plays with several mixtures of propane, ethylene, methane, argon, and nitrogen, with the best results coming from argon and propane in a 70:30 percent ratio. A regenerative counterflow heat exchanger, where the cooled expanding gas flows over the incoming compressed gas to cool it, does most of the heavy lifting here, and is bolstered by a separate compressor that pre-cools the gas mixture to about -30°C before it enters the regenerative system.

There’s also a third compressor system that pre-cools the nitrogen process gas, which is currently supplied by a tank but will eventually be pulled right from thin air by a pressure swing adsorption system — basically an oxygen concentrator where you keep the nitrogen instead of the oxygen. There are a ton of complications in the finished system, including doodads like oil separators and needle valves to control the flow of liquid nitrogen, plus an Arduino to monitor and control the cycle. It works well enough to produce fun amounts of LN₂ on the cheap — about a quarter of the cost of commercially made stuff — with the promise of efficiency gains to come.

It does need to be said that there’s ample room for peril here, especially containing high pressures within copper plumbing. Confidence in one’s brazing skills is a must here, as is proper hydro testing of components. That said, [Hyperspace Pirate] has done some interesting work here, not least of which is keeping expenses for the cryocooler to a minimum.

Continue reading “Low-Cost Cryocooler Pumps Out Cheap DIY Liquid Nitrogen” →

Cold Plasma Torch Produces A Cleansing Flame That Never Consumes

April 28, 2019 by Dan Maloney 20 Comments

It’s basically a lightsaber. Except smaller. And with an invisible blade. And cold to the touch. But other than that, this homebrew cold plasma torch (YouTube, embedded below) is just like the Jedi’s choice in elegant weaponry.

Perhaps we shouldn’t kid [Justin] given how hard he worked on this project – seventeen prototypes before hitting on the version seen in the video below – but he himself notes the underwhelming appearance of the torch without the benefit of long-exposure photography. That doesn’t detract from how cool this build is, pun intended. As [Justin] explains, cold plasma or non-equilibrium plasma is an ionized stream of gas where the electron temperature is much hotter than the temperature of the heavier, more thermally conductive species in the stream. It’s pretty common stuff, seen commercially in everything from mercury vapor lamps to microbial sterilization.

It’s the latter use that piqued [Justin]’s interest and resulted in a solid year of prototyping before dialing in a design using a flyback transformer to delivery the high voltage to a stream of argon flowing inside a capillary tube. The quartz tube acts as a dielectric that keeps electrons from escaping and allows argon to be ionized and wafted gently from the tube before it can reach thermal equilibrium. The result is a faint blue glowing flame that’s barely above room temperature but still has all the reactive properties of a plasma. The video shows all the details of construction and shows the torch in action.

Hats off to [Justin] for sticking with a difficult build and coming through it with an interesting and useful device. We’ve no doubt he’ll put it to good use in his DIY biohacking lab in the coming months.

Continue reading “Cold Plasma Torch Produces A Cleansing Flame That Never Consumes” →

Be A Fire Bender With The Power Of Magnets

July 23, 2018 by Dan Maloney 26 Comments

More often than you think, scientific progress starts with a simple statement: “Huh, that’s funny…” That’s the sign that someone has noticed something peculiar, and that’s the raw fuel of science because it often takes the scientist down interesting rabbit holes that sometimes lead to insights into the way the world works.

[Ben Krasnow] ended up falling down one of those rabbit holes recently with his experiments with magnets and flames. It started with his look at the Zeeman effect, which is the observation that magnetic fields can influence the spectral lines of light emitted by certain sources. In a previous video, [Ben] showed that light from a sodium lamp could be dimmed by a powerful electromagnet. Some of his viewers took exception to his setup, which used an oxy-acetylene flame doped with sodium passing through the poles of the magnet; they thought the effect observed was a simple magnetohydrodynamic effect, and not the Zeeman effect he was supposed to be testing. That led to the experiments in the video below, which started with a candle flame being strongly deflected by the magnet. [Ben] methodically worked through the problem, eliminating variables by going so far as to blow soap bubbles of various gasses within the magnet’s poles to rule out the diamagnetism of oxygen as a cause of the phenomenon. He finally showed that even hot air by itself is deflected, using a simple light bulb and a FLIR camera. It’s good stuff, and well worth a watch.

Spoiler alert: [Ben] is still scratching his head about what’s going on, and we’re looking forward to his conclusions. This isn’t his first rabbit hole expedition, of course; his experiments with creating plasma with high-pressure water were fascinating, as were his DIY superconducting ceramics. Continue reading “Be A Fire Bender With The Power Of Magnets” →

Practical Plasma For Thin-Film Deposition

April 11, 2018 by Dan Maloney 32 Comments

[Nixie] wants to sputter. We know, who doesn’t? But [Nixie] has a specific purpose for his sputtering: thin-film deposition, presumably in support of awesome science. But getting to that point requires a set of tools that aren’t exactly off-the-shelf items, so he’s building out a DIY sputtering rig on the cheap.

If you’re not familiar with sputtering, that’s understandable. In this context, sputtering is a process that transfers particles from one solid to another by bombarding the first solid with some sort of energetic particles, usually electrons or a plasma. When properly controlled, sputtering has applications from mass spectrometry to the semiconductor industry, where it’s used to either deposit thin films on silicon wafers or etch them away selectively.

No matter the application, sputtering needs a stable stream of plasma. [Nixie] has posted a series of articles on his blog walking us through his plasma experiments, from pulling a really strong vacuum to building a high-voltage power supply from a microwave oven transformer. It’s a project that needs a deep well of skills and tools, like glassworking, machining, and high-voltage electronics. Check out the plasma in the video below.

Will [Nixie] be using this for a DIY fab lab? Will it be used to make homebrew LEDs? The world waits to hear.

Continue reading “Practical Plasma For Thin-Film Deposition” →

Particle Introduces New Hardware, Adds Mesh Support

February 13, 2018 by Brian Benchoff 34 Comments

Particle, makers of the WiFi and Cellular IoT modules everyone loves, is introducing their third generation of hardware. The Particle Argon, Boron, and Xenon are Particle’s latest offering in the world of IoT dev boards, and this time they’re adding something amazing: mesh networking.

The three new boards are all built around the Nordic nRF52840 SoC and include an ARM Cortex-M4F with 1MB of Flash and 256k of RAM. This chip supports Bluetooth 5 and NFC. Breaking the new lineup down further, the Argon adds WiFi with an ESP32 from Espressif, the Boron brings LTE to the table with a ublox SARA-U260 module, and the Xenon ditches WiFi and Cellular, relying only on Bluetooth, but still retaining mesh networking. This segmentation makes sense; Particle wants you to buy a ton of the Xenon modules to build out your network, and use either the Argon or Boron module to connect to the outside world.

The form factor of the boards conforms to Adafruit Feather standard, a standard that’s good enough, and much better than gigantic Arduino shields with offset pins.

Of particular interest is the support for mesh networks. For IoT solutions (whatever they may be), mesh networking is nearly a necessity if you have a sufficient number of nodes or are covering a large enough area. The technology going into this mesh networking is called Particle Mesh, and is built on OpenThread. While it’s a little early to see Particle’s mesh networking in action, we’re really looking forward to a real-world implementation.

Preorder pricing for these boards sets the Argon module at $15, the Boron at $29, and the Xenon at $9. Shipping is due in July.