Anodize Aluminum Easily

We’ve all seen brightly-colored pieces of aluminum and can identify them as anodized. But what does that mean, exactly? A recent video from [Ariel Yahni] starring [Wawa] — a four-legged assistant — shows how to create pieces like this yourself. You can see [Wawa’s] new dog tag, below.

[Ariel] found a lot of how to information on using sulphuric acid, but that’s dangerous stuff. One web page we covered years ago, though, discussed a safer chemistry. The process requires lye and a common pool chemical used to decrease pH. Sodium hydroxide isn’t super safe, but it is much less problem to buy, store, and use than battery acid.

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Common Chemicals Combine To Make Metallic Sodium

There’s no debating that metallic sodium is exciting stuff, but getting your hands on some can be problematic, what with the need to ship it in a mineral oil bath to keep it from exploding. So why not make your own? No problem, just pass a few thousand amps of current through an 800° pot of molten table salt. Easy as pie.

Thankfully, there’s now a more approachable method courtesy of this clever chemical hack that makes metallic sodium in quantity without using electrolysis. [NurdRage], aka [Dr. N. Butyl Lithium], has developed a process to extract metallic sodium from sodium hydroxide. In fact, everything [NurdRage] used to make the large slugs of sodium is easily and cheaply available – NaOH from drain cleaner, magnesium from fire starters, and mineral oil to keep things calm. The reaction requires an unusual catalyst – menthol – which is easily obtained online. He also gave the reaction a jump-start with a small amount of sodium metal, which can be produced by the lower-yielding but far more spectacular thermochemical dioxane method; lithium harvested from old batteries can be substituted in a pinch. The reaction will require a great deal of care to make sure nothing goes wrong, but in the end, sizable chunks of the soft, gray metal are produced at phenomenal yields of 90% and more. The video below walks you through the whole process.

It looks as though [NurdRage]’s method can be scaled up substantially or done in repeated small batches to create even more sodium. But what do you do when you make too much sodium metal and need to dispose of it? Not a problem.

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Machine Shop Soaps Are Good, Clean Learning Fun

At first glance, it’s easy to dismiss the creation of custom bath soaps as far outside the usual Hackaday subject matter, and we fully expect a torrent of “not a hack” derision in the comments. But to be able to build something from nothing, a hacker needs to be able to learn something from nothing, and there is plenty to learn from this hack.

On the face of it, [Gord] is just making kitschy custom bath soaps for branding and promotion. Cool soaps, to be sure, and the drop or two of motor oil and cutting fluid added to each batch give them a little machine shop flair. [Gord] experimented with different dyes and additives over multiple batches to come up with a soap that looked like machined aluminum; it turns out, though, that adding actual aluminum to a mixture containing lye is not a good idea. Inadvertent chemical reactions excepted, [Gord]’s soaps and custom wrappers came out great.

So where’s the hack? In stepping way outside his comfort zone of machining and metalwork, [Gord] exposed himself to new materials, new techniques, and new failure modes. He taught himself the basics of mold making and casting, how to deal with ultra-soft materials, the chemistry of the soap-making process, working out packaging and labeling issues, and how to deal with the problems that come from scaling up from prototype to production. It may have been “just soap”, but hacks favor the prepared mind.