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If you where able to make your own Transformer what would it look like?

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LAN_403

Sulaiman

Sun Jan 31 2016, 09:15AM

Registered Member #162 Joined: Mon Feb 13 2006, 10:25AM
Location: United Kingdom
Posts: 3140

more randomness;

I have a large ferrite rod that I made by smashing up random damaged or scrap transformers and TV CRT deflection yokes and a few toroids, and stuffing the result in pvc pipe with polyurethane varnish as a binder
could have been any mix of grades, though mostly MnZn.
(Ferrite; 30mm dia x 400mm, winding; 100 quad-filar turns, one of the filaments being a nylon fishing line
The result is incredibly disappointing :(
it is ok as a moderate Q power inductor but poor as a transformer, even allowing for the open magnetic structure
I left so much space in the core that the q of coils is low ... flux leakage all along the ferrite.
So, I'm fairly sure that you will need to make some kind of really high pressure press to squeeze out internal airgaps

In another thread there was mention of you possibly using NiZn mixes,
given the size of your transformer, length and capacitance of wire, insulation requirements, flux leakage ...
I guess <100 kHz self-resonant windings,
certainly less than frequency where NiZn would be better than MnZn.

And regarding core shapes and cross-sections ... KISS
until enough practice to be confident, so that you do not abandon your project, as I have many ;)

P.S. anyone requiring a trifilar flux-capacitor choke please contact me
I money-back unconditionally guarantee that without one of these (or similar) you will not achieve bi-directional time travel,
PLUS if your claim is explained to my satisfaction and submitted before 2016,
I will pay GBP 1000 cash compensation for the rights.
Only one in stock ... photo's available to serious bidders.
(this is for the Mk.II version, a modification of the one described above which did not work)

Patrick

Sun Jan 31 2016, 10:10PM

Registered Member #2431 Joined: Tue Oct 13 2009, 09:47PM
Location: Chico, CA. USA
Posts: 5639

Planars and ultra-high cross-section area E-cores. Heres Uzzors work :

look at the bottom page.

Buy them or ferrite slabs and youll see.

2Spoons

Mon Feb 01 2016, 12:48AM

Registered Member #2939 Joined: Fri Jun 25 2010, 04:25AM
Location:
Posts: 615

You can simply buy ferrite powder. I think I paid about 70 euro for 2 kg. I don't recall the particle size. This was for work, so I don't have it anymore, and I can't recall who the supplier was. Material choices may be limited.
If you want to get really experimental, you could try making your own ferrite by co-precipitating MnZn or NiZn with magnetite - same way powders for ferrofluids are made. But I think that may be something to try later ...

Patrick

Mon Feb 01 2016, 01:13AM

Registered Member #2431 Joined: Tue Oct 13 2009, 09:47PM
Location: Chico, CA. USA
Posts: 5639

2Spoons wrote ...

You can simply buy ferrite powder.

How do you make it solid ?

Conundrum

Mon Feb 01 2016, 04:59AM

Registered Member #96 Joined: Thu Feb 09 2006, 05:37PM
Location: CI, Earth
Posts: 4059

I'm assuming it has to be oxide free MnZn right? its possible to get MnO2 and ZnO on ebay and then co-fire it with excess carbon to remove all the oxygen.

Chris Cristini

Mon Feb 01 2016, 03:25PM

Registered Member #1749 Joined: Fri Oct 10 2008, 02:04AM
Location: Claremont New Hampshire
Posts: 497

Well I guess the first Decision I have to make is what material I should use for the mold just simple Milled Aluminum or EDM a chunk of steel? I feel it would be cheaper just to use aluminum however I am worried that 10-15 tons will start to deform such soft metal I will see if I could use Sulaiman's Idea of contacting transformer core Companies for any advise If its not some trade secret.

Also we have a heat treating furnace that removes oxygen to prevent scaling and oxidation I could try sintering with that the heat is quite even.

Patrick

Mon Feb 01 2016, 05:53PM

Registered Member #2431 Joined: Tue Oct 13 2009, 09:47PM
Location: Chico, CA. USA
Posts: 5639

your gong to a lot of trouble here.

Chris Cristini

Mon Feb 01 2016, 06:15PM

Registered Member #1749 Joined: Fri Oct 10 2008, 02:04AM
Location: Claremont New Hampshire
Posts: 497

I will just buy ferrite cores as close to what I want. Is there a good way to mill them I never tried and cant find any Information online.

I would guess High RPM slow Feedrate with a ball end mill

Patrick

Mon Feb 01 2016, 07:16PM

Registered Member #2431 Joined: Tue Oct 13 2009, 09:47PM
Location: Chico, CA. USA
Posts: 5639

This might be the one thing tungsten carbide cant do. but I know structured diamond can. (and SiC grinding) so try those in a CNC or manual mill.

1454371725 2431 FT1630 1259044135 2431 Ft80048 Piggies Small

Chris Cristini

Tue Feb 02 2016, 02:29AM

Registered Member #1749 Joined: Fri Oct 10 2008, 02:04AM
Location: Claremont New Hampshire
Posts: 497

Yea found out carbide just goes dull in a hurry.

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