microwave

99 Articles

Microwave Forge Casts The Sinking-est Benchy Ever

September 15, 2024 by 7 Comments

As a test artifact, 3DBenchy does a pretty good job of making sure your 3D printer is up to scratch. As an exemplar of naval architecture, though — well, let’s just say that if it weren’t for the trapped air in the infilled areas, most Benchy prints wouldn’t float at all. About the only way to make Benchy less seaworthy would be to make it out of cast iron. Challenge accepted.

We’ve grown accustomed to seeing [Denny] over at “Shake the Future” on YouTube using his microwave-powered kilns to cast all sorts of metal, but this time he puts his skill and experience to melting iron. For those not in the know, he uses standard consumer-grade microwave ovens to heat kilns made from ceramic fiber and lots of Kapton tape, which hold silicon carbide crucibles that get really, really hot under the RF onslaught. It works surprisingly well, especially considering he does it all on an apartment balcony.

For this casting job, he printed a Benchy model from PLA and made a casting mold from finely ground silicon carbide blasting medium mixed with a little sodium silicate, or water glass. His raw material was a busted-up barbell weight, which melted remarkably well in the kiln. The first pour appeared to go well, but the metal didn’t quite make it all the way to the tip of Benchy’s funnel. Round two was a little more exciting, with a cracked crucible and spilled molten metal. The third time was a charm, though, with a nice pour and complete mold filling thanks to the vibrations of a reciprocating saw.

After a little fettling and a saltwater bath to achieve the appropriate patina, [Denny] built a neat little Benchy tableau using microwave-melted blue glass as a stand-in for water. It highlights the versatility of his method, which really seems like a game-changer for anyone who wants to get into home forging without the overhead of a proper propane or oil-fired furnace. Continue reading “Microwave Forge Casts The Sinking-est Benchy Ever” →

The Waveguide Explanation You Wish You’d Had At School

August 9, 2024 by 13 Comments

Anyone who has done an electronic engineering qualification will at some point have had to get to grips with transmission lines, and then if they are really lucky, waveguides. Perhaps there should be one of those immutable Laws stating that for each step in learning about these essential parts, the level of the maths you are expected to learn goes up in an exponential curve, for it’s certainly true that most of us breathe a hefty sigh of relief when that particular course ends. It’s not impossible to understand waveguides though, and [Old Hack EE] is here to slice through the formulae with some straightforward explanations.

First of all we learn about the basics of propagation in a waveguide, then we look at the effects of dimension on frequency. Again, there’s little in the way of head-hurting maths, just real-world explanations of cutt-off frequencies, and of coupling techniques. For the first time we’ve seen, here are simple and understandable explanations of the different types of splitter, followed up by the famous Magic T. It’s all in the phase, this is exactly the stuff we wish we’d had at university.

The world needs more of this type of explanation, after all it’s rare to watch a YouTube video and gain an understanding of something once badly taught. Take a look, the video is below the break.

Continue reading “The Waveguide Explanation You Wish You’d Had At School” →

Print Wave Metal Casting

July 13, 2024 by 4 Comments

Direct 3D printing of metal remains out of reach for the hobbyist at the moment, so casting is often the next best thing, particularly given the limitations of 3D printed metals. [Denny] from Shake the Future shows us how to simplify the process with “print wave metal casting.”

The first step of printing a PLA object will seem familiar to any 3D print to metal process, but the main differentiator here is pouring the investment casting on the printer build plate itself. We like how he used some G-code to shake the build plate to help remove bubbles. Once the plaster solidifies, the plastic and mold are placed in the microwave to soften the plastic for removal.

The plaster is dried in an oven (or air fryer) and then [Denny] bolts the mold together for the casting process. Adding a vacuum helps with the surface finish, but you can always polish the metal with a generous helping of elbow grease.

If [Denny] seems familiar, you might remember his very detailed breakdown of microwave casting. We’ve seen plenty of different approaches to metal casting over the years here. Need a part in another material? How about casting concrete or resin?

Thanks to [marble] on the Hackaday Discord for the tip!

Continue reading “Print Wave Metal Casting” →

So Much Going On In So Few Components: Dissecting A Microwave Radar Module

July 1, 2024 by 17 Comments

In the days before integrated circuits became ubiquitous, providing advanced functionality in a single package, designers became adept at extracting the maximum use from discrete components. They’d use clever circuits in which a transistor or other active part would fulfill multiple roles at once, and often such circuits would need more than a little know-how to get working. It’s not often in 2024 that we encounter this style of circuit, but here’s [Maurycy] with a cheap microwave radar module doing just that.

Continue reading “So Much Going On In So Few Components: Dissecting A Microwave Radar Module” →

Powering Airplanes With Microwaves: An Aviation Physics Challenge Amidst Many

June 27, 2024 by 19 Comments

Falling firmly under the fascinating science category of ‘What if…?’ comes the idea of powering airplanes with beamed microwaves. Although the idea isn’t crazy by itself, since we can even keep airplanes flying using just solar power (though with no real useful payload), running through the numbers as [Ian McKay] does in a recent article in IEEE Spectrum makes it clear that there are still some major hurdles if we want to make such a technology reality. Yet is beamed microwave power that much more far out than other alternative ways to power aviation?

Most of the issues are rather hard limits with the assumed technology (phased microwave arrays), with the need for 170 meter diameter ground transmitters every 100 km along the route (including floating transmitters on the oceans with massive power cables, apparently). Due to the limited surface area on something like a Boeing 737-800 you’d need to cram the full take-off power needs (~30 MW) on its ~1,000 m2 surface area available for receiver elements, or 150 Watt per rectifying antenna (rectenna) element assuming a wavelength of 5 cm.

The good news is that the passengers inside would probably survive if the microwave-like shielding keeps up, and birds passing through the beams are likely to survive if they’re fast enough. It’d ruin a whole part of the local radio spectrum from leaked microwaves, of course. Unfortunately beaming MW levels of microwaves across 100 km is still beyond our capabilities.

After this fun science session, [Ian] then looks at alternatives like batteries and hydrogen, neither of which come even close to the energy density (or relative safety) of commercial aviation fuels. Perhaps synthetic aviation fuel might be the ticket, but at this point beamed microwave power is as likely to replace aviation fuel as batteries or hydrogen, though more likely than countries like the United States building out a fast & cheap high-speed rail network.

More Microwave Metal Casting

April 16, 2024 by 10 Comments

If you think you can’t do investment casting because you don’t have a safe place to melt metal, think again. Metal casting in the kitchen is possible, as demonstrated by this over-the-top bathroom hook repair using a microwave forge.

Now, just because it’s possible doesn’t mean it’s advisable. There are a lot better ways to fix something as mundane as a broken bathroom hook, as [Denny] readily admits in the video below. But he’s been at the whole kitchen forging thing since building his microwave oven forge, which uses a special but easily constructed ceramic heat chamber to hold a silicon carbide crucible. So casting a replacement hook from brass seemed like a nice exercise.

The casting process starts with a 3D-printed model of the missing peg, which gets accessories such as a pouring sprue and a thread-forming screw attached to it with cheese wax. This goes into a 3D-printed mold which is filled with a refractory investment mix of plaster and sand. The green mold is put in an air fryer to dry, then wrapped in aluminum foil to protect it while the PLA is baked out in the microwave. Scrap brass gets its turn in the microwave before being poured into the mold, which is sitting in [Denny]’s vacuum casting rig.

The whole thing is over in seconds, and the results are pretty impressive. The vacuum rig ensures metal fills the mold evenly without voids or gaps. The brass even fills in around the screw, leaving a perfect internal thread. A little polishing and the peg is ready for bathroom duty. Overly complicated? Perhaps, but [Denny] clearly benefits from the practice jobs like this offer, and the look is pretty cool too. Still, we’d probably want to do this in the garage rather than the kitchen.
Continue reading “More Microwave Metal Casting” →

A Look Inside A 70-GHz Electromechanical Attenuator

March 15, 2024 by 4 Comments

It might not count as “DC to daylight,” but an electromechanical attenuator that covers up to 70 GHz is pretty close, and getting a guided tour of its insides is quite a treat.

Perhaps unsurprisingly, this one comes to us from [Shahriar] at “The Signal Path,” where high-end gear most of us never get a chance to work with goes for one last hurrah after it releases the magic smoke. And indeed, that appears to be exactly what happened to the Rohde & Schwarz 75 dB step attenuator, a part that may have lived in the front end of one of their spectrum analyzers. As one would expect from such an expensive component, the insides have some pretty special engineering. The signal is carried through the five attenuation stages on a narrow strip of copper. Each stage uses a solenoid to move the strip between either a plain conductor or a small Pi pad with a specified attenuation. The attention to detail inside the cavity is amazing, with great care taken to maintain the physical orientation of the stripline to prevent impedance mismatches and unwanted reflections.

The Pi pads themselves are fascinating, too, especially under [Shahriar]’s super-duper microscope. All of them were destructively removed from the cavity before getting to him, but it’s still pretty clear what’s going on. That’s especially true with the 5-dB pad, which bears clear signs of the overload that brought on the demise of the whole attenuator. We suppose a repair would have been feasible if it had been just the one pad that needed replacement, but with all of them broken, it’s off to the scrap bin. Or to the recycler — there appears to be plenty of gold in there.

We thought this was a fantastic look under the covers of an exquisitely engineered part. Too bad it didn’t rate the [Shahriar] X-ray treatment, as this multimeter repair or this 60-GHz phased array did. Oh, well — maybe next time.

Continue reading “A Look Inside A 70-GHz Electromechanical Attenuator” →