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Registered Member #1749
Joined: Fri Oct 10 2008, 02:04AM
Location: Claremont New Hampshire
Posts: 497
What a beautiful and useful thread. And I like your design simple and too the point with no need to spend hours in solid works. As the pressing goes I was thinking about using my 10 ton bottle jack and building a simple Mild steel jig for it all maybe I should design that in Solid works too. Also I don't know much about the microwave sintering process but I will experiment. EDIT: there is a lot of information on YouTube that supports the Microwave sintering process. And how about just taking a bunch of ferrite cores that are already made and grind them then re sinter?
Registered Member #162
Joined: Mon Feb 13 2006, 10:25AM
Location: United Kingdom
Posts: 3140
A square centre limb is more efficient due to winding space, leakage flux etc. hexagonal better, circular best. so the outside limbs are 1/2 a square.
P.S. it is better if you avoid winding directly over an airgap, (fringing flux, eddy currents, heating etc.) (plus fringing flux x current in wire = Fleming's left-hand rule = vibration) e.g. two 1/2 length bobbins are easier to wind and avoid the airgap.
Registered Member #1749
Joined: Fri Oct 10 2008, 02:04AM
Location: Claremont New Hampshire
Posts: 497
Thank you Sulaiman I had allot of practice When I was designing Infrared Black top equipment. I even designed a new rear end suspension that I welded together and it worked great Until I had to scrap the truck.
I will make up some other Transformer designs and maybe have a vote for the first one I build in real life once I get the stuff together and experiment with core material.
I think it would be cool to mix red iron oxide to make the core red?
Registered Member #1749
Joined: Fri Oct 10 2008, 02:04AM
Location: Claremont New Hampshire
Posts: 497
Here is a new E core does not look like much but it is larger than a MOT.
I might add oil cooling to this as well.
I just experimented with a Microwave and put a good sized Ferrite TV yoke core and with in 5 Seconds it started getting very hot. Microwave sintering might be the best way all though it might be harmful to the magnetron. Here is a list of useful YouTube videos on Powder Metallurgy.
Registered Member #1749
Joined: Fri Oct 10 2008, 02:04AM
Location: Claremont New Hampshire
Posts: 497
Wow I forgot how interesting this thread is to read No better time than now to try all of this stuff I am going to push this to the top of my list of projects and design some more you can delete that new thread I started if you want I am going to do more research and gather the parts for a Sintering furnace and maybe regrind ferrites until I have 5 or 10 pounds of powder :) It is sad I have had so many times in my life I had to give up all my projects I could not imagine where I would be if I kept all of my stuff.
Registered Member #162
Joined: Mon Feb 13 2006, 10:25AM
Location: United Kingdom
Posts: 3140
Just had a thought, you could make the core from a single continuous 'I' core in the middle of the coil former and longer than the former and 1,2,3 or 4 'C' shaped pieces around the outside. This may be easier to make and there would be no gap inside the coils.
[|]
On a separate note, LARGE ferrite rods would be purchased by vlf/ulf radio experimenters. e.g. 1" dia x 12" long
I'm not sure if grinding is the best way to get powdered ferrite, a disposable super-blender or a ball mill may be better due to oxidation problems... just guessing
I'd be tempted to write to fair-rite and other manufacturers to see if they can help with your experiments. even floor-sweepings would be a good start, 1kg of their finest mix would be negligible cost to them in return for a write up here. For sure if you don't ask you won't get, and you may get technical help too, worth a try ?
Registered Member #1749
Joined: Fri Oct 10 2008, 02:04AM
Location: Claremont New Hampshire
Posts: 497
Sulaiman wrote ...
Just had a thought, you could make the core from a single continuous 'I' core in the middle of the coil former and longer than the former and 1,2,3 or 4 'C' shaped pieces around the outside. This may be easier to make and there would be no gap inside the coils.
[|]
On a separate note, LARGE ferrite rods would be purchased by vlf/ulf radio experimenters. e.g. 1" dia x 12" long
I'm not sure if grinding is the best way to get powdered ferrite, a disposable super-blender or a ball mill may be better due to oxidation problems... just guessing
I'd be tempted to write to fair-rite and other manufacturers to see if they can help with your experiments. even floor-sweepings would be a good start, 1kg of their finest mix would be negligible cost to them in return for a write up here. For sure if you don't ask you won't get, and you may get technical help too, worth a try ?
That is a good and interesting idea and looking at the ferrite rods on eBay the price isn't too bad what about making it look like a long LOPT Core? [___]
And reaching out to manufactures with experience in this is a great idea too thank you I think that with a little hard work and experimenting with different mixes and temperatures will lead to something great and with all of the equipment i have access to now should make this more feasible for me to do.
Also milling ferrite is a great to because I could have control of feed rate and not just destroying it from end mills grabbing to much and just snapping the brittle material I didn't think of that great stuff. I am sure the powder from that would be a great mess to clean
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If you where able to make your own Transformer what would it look like?
And I like your design simple and too the point with no need to spend hours in solid works. As the pressing goes I was thinking about using my 10 ton bottle jack and building a simple Mild steel jig for it all maybe I should design that in Solid works too. Also I don't know much about the microwave sintering process but I will experiment. EDIT: there is a lot of information on YouTube that supports the Microwave sintering process. And how about just taking a bunch of ferrite cores that are already made and grind them then re sinter?
