When Is Damascus Steel Not From Damascus?

If you grow up around a working blacksmith’s forge, there are a few subjects related to metalwork on which you’ll occasionally have a heated discussion. Probably the best known is the topic of wrought iron, a subject I’ve covered here in the past, and which comes from the name of a particular material being confused with a catch-all term of all blacksmith-made items. I’ve come to realise over recent years that there may be another term in general use which is a little jarring to metalwork pedants, so-called Damascus steel. Why the Syrian capital should pop up in this way is a fascinating story of medieval metalworking, which can easily consume many days of research.

Damascus? Where’s That?

A section of a knife blade with various silver grey and black layered patterns in the metal.
The banded pattern of the laminate formed from pattern welded layers of differing steels in a modern Damascus steel knife. “DamaszenerKlinge” by Soerfm

The Damascus steel you’ll see in YouTube videos, TV shows, and elsewhere is a steel with complex bands and striations on its surface. It’s often used in knife blades, and it will usually have been chemically treated to enhance the appearance of the patterns. It’s a laminate material made by pattern welding layers of different steels together, and it will usually have been worked and folded many times to produce a huge number of very thin layers of those steels. Sometimes it’s not made from sheets or ingots of steel but from manufactured steel products such as chains, in an attempt to produce a result with more unusual patterns. Continue reading “When Is Damascus Steel Not From Damascus?”

No Need To Buy A Woodchipper – Build One!

Polish YouTuber WorkshopFromScratch finally got fed up with tripping over piles of garden detritus and decided to have a go at building a woodchipper (Video, embedded below). Since they had a ‘small’ 1.5kW gearmotor just lying idle (as you do) it was an obvious fit for a machine that needs torque rather than supersonic speed. The video is a fabulous 20-minute journey through the workshop showing just about every conceivable metalworking tool being used at some point.

Checkout out the thickness of my blades!

One interesting point is the bottom roller, which sits between a pair of removable guides, which should help the thing self-feed without jamming. Whether that was necessary is not for us to judge, but it can’t hurt. The frame looks like it was constructed from at least 1/4″ thick steel, which is expensive if you don’t happen to have a supply to hand. There’s lots to see, everything from thin sheet metalworking, which was plasma cut, constructing the feed and exhaust guides, to box sections being skilfully welded at some interesting angles to make a cart to move the thing. They tell us the blades were constructed from some seriously thick slabs of C45 grade steel, but currently are not hardened. This is planned for the future, but we suspect not something that is easily achieved in the home workshop!

If this channel is familiar, then you might remember the earlier stump grinder they built. If you are drowning in sawdust, but have a log burner, then you’ll appreciate this sawdust briquette machine.

Continue reading “No Need To Buy A Woodchipper – Build One!”

Steel For Your Fighting Robot

The job of processing video after a large event must be a thankless one for whichever volunteer upon whose shoulders it falls, and thus it’s not unusual for talks at larger events to end up online much later than the event itself. Electromagnetic Field 2022 was last year, but they have continued to drop new videos. Among the latest batch is one from [Jennifer Herchenroeder], in which she discusses the steel used in her team’s BattleBot, Hijinx (Edit: her EMF talk was cut short due to time pressures, so she re-recorded it in full after the event and we’ve replaced the link. The EMF video meanwhile is here). The result is a fascinating introduction to the metallurgy of iron and steel, and is well worth a watch.

To fully understand the selection of armor steel it’s necessary to start from first principles with iron, to look at its various allotropes, and understand something of how those allotropes form and mix in the steel making and metalworking processes. We’re treated to a full description of the various tempering and hardening processes, before a panel-by-panel rundown of the various steels used by Hijinx.

For a Hackaday writer with a past in robot combat it’s fascinating to see how the design of robots has evolved over the decades since the British Robot Wars, and it’s particularly nice to see the current generation as part of our community. However, if you’ve tempted yourself, bear in mind that it’s not all plain sailing.

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Gas-Powered Fly Swatter Slightly Over-Engineered

Any good flyswatter ought to be able to break through a hefty piece of wood. At least, that is how [Finn] explains the design philosophy behind this enormous, overpowered flyswatter. Although we don’t know if everyone needs as robust a machine as this to deal with a minor annoyance like a house fly, we can certainly appreciate the over-engineered, extremely powerful (and dangerous) machine that can swat flies but also break through a two-by-four with ease.

The build comes to us in two parts, with the first part documenting the construction of some of the parts of the flyswatter, including the piston-driven gas cylinder. As a bit of a tangent, [Finn] first tests this part by using it to shoot lemons at pieces of plywood. After this initial testing of the gas cylinder, a cam mechanism is installed on the top, and the gas cylinder is slightly modified to pull on a piece of Dyneema rope attached to the cam. At the other end of the rope is a long metal lever with the flyswatter on the end, in this case, made out of a sheet of laser-cut plate steel.

With the addition of a few safety features, like a spring-assisted bumper to keep the flyswatter from swinging too far and hitting its operator, the machine is ready for use. It also eventually received some other upgrades as well including extra weights to prevent the flyswatter from bouncing after firing and a reinforced metal rod to hold the flyswatter after its demonstrations on various dimensional lumber destroyed it. In all likelihood, this is the largest insect-control device we’ve seen since this microwave-powered bug zapper. Now if you are building an insect

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Retrotechtacular: Understanding The Strength Of Structural Shapes

Strength. Rigidity. Dependability. The ability to bear weight without buckling. These are all things that we look for when we build a mechanical structure. And in today’s Retrotechtacular we take a closer look at the answer to a question: “What’s in A Shape?”

As it turns out, quite a lot. In a wonderful film by the prolific Jam Handy Organization in the 1940’s, we take a scientific look at how shape affects the load bearing capacity of a beam. A single sided piece of metal, angle iron, C-channel, and boxed tubing all made of the same thickness metal are compared to see not just just how much load they can take, but also how they fail.

The concepts are then given practical application in things that we still deal with on a daily basis: Bridges, cars, aircraft, and buildings. Aircraft spars, bridge beams, car frames, and building girders all benefit from the engineering discussed in this time capsule of film.

None of the concepts in this video are suddenly out of date, because while our understanding of engineering has certainly progressed since this film was made, these basic concepts remain the same. As such, they will apply to any structural or mechanical devices that we make, be it 3d printed, CNC routed, welded, glued, vacuum formed, zip tied, duct taped, bailing wired, or hot glued.

Keep your eyes open for a wonderful sights and sounds of a rare Boeing 314 Clipper landing on water and a 1920’s Buffalo Springfield Steam Roller demonstrating how wonderful the film’s sponsor, Chevrolet, makes their automobile frames.

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Hackaday Links: October 31, 2021

Global supply chain issues are beginning to hit closer to home for the hacker community, as Raspberry Pi has announced their first-ever price increase on their flagship Pi 4. The move essentially undoes the price drop on the 2GB version of the Pi 4 that was announced in February, and sets the price back up from $35 to $45. Also rolled back is the discontinuation of the 1GB version, which will now be available at the $35 price point. The announcements come from Eben Upton himself, who insists the price increase is only temporary. We applaud his optimism, but take it with a grain of salt since he also said that 2021 production across the board will stay at the seven million-unit level, which is what they produced in 2020. That seems to speak to deeper issues within the supply chain, but more immediately, it’s likely that the supply of Pi products will be pinched enough that you’ll end up paying above sticker price just to get the boards you need. Hope everyone is stocked up.

On the topic of supply chain issues and their threat to Christmas gift-giving, here’s one product we hope is stranded in a container off Long Beach or better still, bobbing along in the Strait of Juan De Fuca: a toddler’s toy telephone that actually makes and receives calls. Anyone born in the last 60 years probably had one of the Fisher-Price Chatter telephone, a toy that in its original form looked like a desk telephone on wheels that was dragged behind the child, popping along and providing endless hours of clicky amusement as kids twisted the dial and lifted the receiver. Come to think of it, the Chatter telephone may be as close to a dial phone as anyone born since 1990 may have come. Anyway, some genius stuck a Bluetooth module into the classic phone to let it hook up to an app on an actual phone, allowing kids (or more likely their nostalgia-soaked parents) to make and receive calls. It’s actually priced at a reasonable $60, so there might be some hacking potential here.

Also tangential to supply chains, we stumbled across a video guide to buying steel that might interest readers. Anyone who has seen the displays of steel and other metals at the usual big-box retailers might wonder what the fuss is, but buying steel that way or ordering online is a great way to bust a project’s budget. Fabricator and artist Doug Boyd insists that finding a local steel supplier is the best bang for your buck, and has a bunch of helpful tips for not sounding like a casual when you’re ordering. It’s all good advice, and would have helped us from looking foolish a time or two at the metal yard; just knowing that pipe is measured by inside diameter while tubing is measured by outside dimensions is worth the price of admission alone.

With all the money you save on steel and by not buying Raspberry Pis, perhaps you’ll have a couple of hundred thousand Euros lying around to bid on this authentic 1957 Sputnik I satellite. The full-scale model of Earth’s first artificial satellite — manhole covers excluded — was a non-flown test article, but externally faithful to the flown hardware that kicked off the first Space Race. The prospectus says that it has a transmitter and a “modern power supply”; it’s not clear if the transmitter was originally part of the test article or added later. The opening bid is €85,000 and is expected to climb considerably.

And finally, there’s something fascinating about “spy radios,” especially those from the Cold War era and before, when being caught with one in your possession was probably going to turn out to be a very bad day. One such radio is the Radio Orange “Acorn” receiver, which is in the collection of the Crypto Museum. The radio was used by the Dutch government to transmit news and information into the occupied Netherlands from their exile in London. Built to pass for a jewelry box, the case for the radio was made from an old cigar box and is a marvel of 1940s miniaturization. The radio used three acorn-style vacuum tubes and was powered by mains current; another version of the Radio Orange receiver was powered by a bike dynamo or even a water-powered turbine, which could be run from a tap or garden hose. The video below shows the water-powered version in action, but the racket it made must have been problematic for its users, especially given the stakes.

Continue reading “Hackaday Links: October 31, 2021”

Big homemade lathe

Heavy Metal Lathe Build Doesn’t Spare The Steel

It’s common wisdom that the lathe is the essential machine tool, and the only one that can make copies of itself. While we won’t argue the primacy of the lathe in the machine shop, this scratch-built, heavy-duty lathe gives the lie to the latter argument — almost.

We’re used to seeing homebrew lathes, of course, and we’ve featured more than a few of them before. But two things make [Jornt]’s build stand out: how few specialized tools were needed to build it, and the sheer size and bulk of the finished product. Where most homebrew lathes tend to be the bench top variety and feature cast aluminum parts, [Jornt] went with steel for his build, and a lot of it. The base and bed of the machine are welded from scrap steel I-beams, and the ways are made from angle iron that has been ground flat with a clever jig to hold an angle grinder. The angle grinder plays a prominent role in the build, as do simple tools like a hand drill, files, and a welder — and yes, the unfinished lathe itself, which was used to bore out the bearing blocks for the headstock.

The completed lathe, powered by a treadmill motor in a way that [Jeremy Fielding] would no doubt endorse, comes in at a beefy 450 kg. It honestly looks like something you could buy from a catalog, and has most of the features of commercial machines. One thing we’d love to see on this lathe is the electronic lead screw that [James Clough] developed for his off-the-shelf lathe.

Continue reading “Heavy Metal Lathe Build Doesn’t Spare The Steel”