spark

14 Articles

Hackaday Prize 2023: Machining Metals With Sparks

August 8, 2023 by 3 Comments

Working with metals can present a lot of unique challenges even for those with a fairly well-equipped shop. Metals like aluminum and some types of steel can be cut readily with grinders and saws, but for thick materials or some hardened steels, or when more complex cuts need to be made, mechanical cutting needs to be reconsidered in favor of something electric like electrical discharge machining (EDM) or a plasma cutter. [Norbert] has been on the path of building his own EDM machine and walks us through the process of generating a spark and its effects on some test materials.

Armed with a microscope, a homemade high-voltage generator, drill bit, and a razor blade to act as the workpiece, [Norbert] begins by experimenting with electrical discharges by bringing the energized drill bit close to the razor to determine the distance needed for effective electrical machining. Eventually the voltage is turned up a bit to dive into the effects of higher voltage discharges on the workpiece. He also develops a flushing system using de-ionized water, and then finally a system to automate the discharges and the movement of the tool.

While not a complete system yet, the videos [Norbert] has created so far show a thorough investigation of this metalworking method as well as some of the tricks for getting a setup like this working. EDM can be a challenging method for cutting metal as we’ve seen before with this similar machine which uses wire as the cutting tool, but some other builds we’ve seen with more robust electrodes have shown some more promise.

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Recreating Ben Franklins kite experiment with a drone

Drone Replaces Kite In Recreation Of Famous Atmospheric Electricity Experiment

October 1, 2021 by 4 Comments

Finally, someone decided to answer the question that nobody was asking: what if [Benjamin Franklin] had had a drone rather than a kite?

Granted, [Jay Bowles] didn’t fly his electricity-harvesting drone during a thunderstorm, but he did manage to reach some of the same conclusions that [Dr. Franklin] did about the nature of atmospheric electricity. His experimental setup was pretty simple: a DJI Mini2 drone with enough payload capacity to haul a length of fine-gauge magnet wire up to around 100 meters above ground level. A collecting electrode made of metal mesh was connected to the wire and suspended below the drone. Some big nails were driven into the soil to complete the circuit between the drone and the ground.

[Jay] went old-school for a detector, using a homemade electroscope to show what kind of static charge was accumulating on the electrode. Version 1 didn’t have enough oomph to do much but deliver a small static shock, but a larger electrode was able to deflect the leaves of an electroscope, power a beer can version of a Franklin bell, and also run a homemade corona motor. [ElectroBOOM] makes a guest appearance in the video below to explain the physics of the setup; curiously, he actually managed to get away without any injuries this time. Continue reading “Drone Replaces Kite In Recreation Of Famous Atmospheric Electricity Experiment” →

Air Cannon Serves Up A Blast Of Ferrocerium Sparks

October 15, 2020 by 25 Comments

OK, looks like we have a new way to entertain the kids and wreak havoc in the neighborhood, if this spark-shooting ferrocerium cannon is as easy to build as it looks.

This one comes to us by well-known purveyor of eyebrow-singing projects [NightHawkInLight], whose propane torch never seems to get a break. The idea here is a large scale version of an apparently popular trick where the “flints” from lighters, which are actually rods of ferrocerium, an aptly named alloy of iron and cerium, are heated to a nearly molten state and dropped onto a hard surface. The molten alloy thence explodes in a shower of sparks, to the mirth and merriment of those in attendance.

[NightHawkInLight]’s version of the trick scales everything up. Rather than lighter flints, he uses ferrocerium rods from firestarters of the type used for camping. The rod is stuffed into a barrel formed from steel brake line which is connected to the output of a PVC air chamber. His ominpresent propane torch is attached in such a way as the flame plays upon the loaded pyrophoric plug, heating it to a molten state before the air is released from the chamber. The massive display of sparks seen in the video below is pretty impressive, but we’re getting tired of  gender reveal parties and forest fires.  We just hope he had fire extinguishers on hand.

Seriously, be careful with stuff like this. [NightHawkInLight] has a lot of experience working with these kinds of projects, from his plasma-propelled soda bottles to making synthetic rubies with an arc welder. We’re sure he wouldn’t want to see anyone get hurt.

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Lightning Generator From Electric Lighter

June 5, 2018 by 16 Comments

Generating high voltages isn’t too hard. A decent transformer will easily get you into the 100s of kilovolts, provided you’re a power company and have access to millions of dollars and a substation to put it. If you want to go above that then things start getting difficult, and most tend to look in other places for high voltages such as voltage multipliers.

These devices use nothing but capacitors and diodes, as [Jay] from [Plasma Channel] shows us how to build a small desktop version of a voltage multiplier that can produce almost 70 kV. That’s enough to throw a substantial spark, powered by nothing but a rechargable battery found in an electric lighter. They can also be cheaper than transformers to a point, since they require less insulation and less copper and iron. The voltage multiplier works in stages, with each stage boosting the voltage to a critical level above the stage before it similar to a Marx generator.

Similar designs are used by laboratories to simulate lightning strikes, and can generate millions of volts. They’re a cost-effective way of generating huge voltage pulses and studying everything from the effects of lightning on various equipment to generating X-rays in fusion power tests. We’ve even seen them in use in lasers.

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Cooking With The Awesome Power Of Plasma!

May 8, 2017 by 23 Comments

There is something special about food that has been cooked in a grill, barbecue, or broiler. The charred surface brings both flavour and texture to the food, that other cooking methods fail to emulate. Of course, should you come from a part of the world in which the locals steam their hamburgers those are fighting words, but for [Robots Everywhere] the prospect of a flaccid patty cooked in a microwave oven was too much.

His solution? Broil the microwaved meat in double-quick time, using a plasma arc generated with a high voltage supply. The patty is placed in a grounded metal frying pan, and the high voltage probe is run over each side with accompanying plasma and sparks to lend that essential grilled exterior.

The power supply is a fairly simple affair, if a little hair-raising. A simple push-pull MOSFET oscillator drives a pair of flyback transformers whose secondaries are connected in series. It’s not the most efficient way to generate high voltages with a flyback transformer – the key is in the word “flyback” – but it generates enough juice for the job in hand.

It’s hardly the safest cooking method, and we’d be worried about contamination from whatever metal the electrode is made from. But it’s entertaining to watch, as you’ll be able to see from the video below the break.

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Spark Goes Cellular With The Electron

February 25, 2015 by 53 Comments

A few years ago, small and cheap WiFi modules burst onto the scene and with that the Spark was born. It’s a tiny dev board with a TI CC3000 WiFi module, capable of turning any device into an Internet-connected device. It’s only the very beginning of the Internet of Things, yes, but an important step in the right direction. Now, Spark is unshackling itself from WiFi networks with the Spark Electron, a dev kit that comes with a cellular radio and data plan.

If you’ve ever tried to build a high altitude balloon, a project that will be out of range of WiFi, or anything else where cellular data would be a godsend, you’ll quickly realize Verizon, AT&T, Sprint, and all the other carriers out there don’t necessarily care about your project. As far as we can tell, Spark is the first company to fix this gaping hole in what cellular can do by offering their own service – 20,000 messages for $3/month and no contracts. Officially, that’s 1MB of data spread over 20k messages that are about 50 bytes in length.

There are a few dozen companies and organizations working on the next generation of The Internet Of Things, but these require completely new silicon and spectrum allocations or base stations. Right now, there’s exactly one way of getting a Thing on the Internet without WiFi, and that’s with cellular data. We have to hand it to Spark for this one, and can’t wait to see the projects that will be possible due to a trickle of Internet everywhere.

SuperBowlLamp

Super Bowl Football Lamp Keeps You Informed

February 4, 2015 by 7 Comments

[David] loves to watch football. After his preferred team lost the playoffs, he wanted another reason to watch the big game last Sunday. He ended up building himself a football-shaped lamp that changes color based on who scored last.

[David] started with a Spark Core and a Spark Button. The Spark is the primary microcontroller and includes WiFi. The Spark Button is essentially a shield for the Spark that includes an accelerometer, some LEDs, and a few push buttons. The other part of this build was the housing. [David] used a toy football he got for free as swag from a parade.

As for the code, [David] started by first learning how to control the LEDs on the Spark Button. Then he wrote his own touchdown function to illuminate the football a specific color. Since the Spark uses the REST API, [David] is able to trigger this function by simply visiting the URL of his Spark. This makes it very simple to trigger the event.

The final part of this build was made easy thanks to IfThisThenThat (IFTTT). This is a web service that allows you to monitor and interact with various online web services. It can monitor one service, and then interact with another based on events that happen in the first service. In this case, [David] is using a “channel” added to IFTTT by ESPN. This channel can trigger when certain events happen for whatever team you specify. For this project [David] is monitoring touchdowns.

After combining all of these various services, [David] had a working light that would change colors based on which team scored. He did notice that IFTTT has anywhere between a 1 and 15 minute delay, and he hopes to improve upon this design by hooking directly to an API and skipping the extra service altogether.