RotoMax Rotary Engine... Tesla - Wankel - Mason HHO Hybrid

[evolvingape]

Hi Everyone,

Here is the 01 to Rotary Moment Energy Conversion System

I have shown a 4 Dish System in the diagram as the system is modular.

The Powerdish would take the energy from the Sun and convert it straight to DC removing the need for a rectifier and simplifying the design.

The DC output from the Powerdish would power the Dry Cell Bank directly producing fuel in the form of HHO.

The HHO output from the Dry Cell Bank would become the input to the LFV, this would then be converted to High Velocity Fluid.

The High Velocity Fluid would be used as the input to the Rotary Turbine, which would convert it to Rotary Moment.

This system would allow you to take the Potential Difference energy supplied free of charge by nature, and provide a Rotary Moment output, instead of the traditional Electrical or Heat outputs.

So...

You harness something you get for free, and turn it into clean fuel. You blow this fuel up and convert it to high velocity fluid. You make this high velocity fluid turn a rotary turbine.

The rotary system output will be free to you, unless there is a tax slapped on sunlight! 

Should the HHO act as a system input energy amplifier, as I suspect it will, the system output may well be overunity. If it is, the Rotary Moment can be used to create exponential energy growth as shown here:

http://www.rumormillnews.com/cgi-bin/archive.cgi?noframes;read=184723

RM

[evolvingape]

Hi Everyone,

Quick update for anyone considering a compressed air application for RotoMax testing.

Below is information on Belleville washers (or springs) from this site:

http://www.leespring.com/uk_int_learn_belleville_wash.asp

Single: One washer
Parallel: All washers stacked the same way
Series: All washers stacked opposite each other
Series-Parallel: A combination of the two

A single Belleville Spring Washer has a specific load for a given deflection. Two washers stacked in parallel will yield double the load of a single washer for the same deflection;three washers will yield triple the load; four washers will yield four times the load, etc. Alternatively, two washers stacked in series will yield double the deflection of a single washer for the same load; three washers will yield triple the deflection; four washers will yield four times the deflection, etc.Various series-parallel combinations therefore can provide a wide variety of combined results of load versus deflection for the stack. Consequently, depending upon the application, the designer can:

• Stack in "parallel" to increase load
• Stack in "series" to increase deflection
• Adjust the load and deflection of a washer stack by adding or removing individual
   washers and/or the sequence in which they are used, whether in series or parallel.

This information will help you when adjusting the regulator pressure on a paintball tank. I personally believe Series â€" Parallel is the way to go with a minimum of 2 washers in each stage to prevent the rapid cycling and high pressure changes from crushing the washers.

Add washers to increase pressure, remove washers to reduce pressure. Construct a pressure testing assembly using a K valve, a non return valve, a tee, and a pressure gauge. The K valve acts as the pressure relief valve when the trigger is pressed to release the pressure.

A compressor would be handy as testing of different spring pressures requires the cylinder to be emptied and filled repeatably. However if you don't have access to a compressor at 3000 psi then there is another option:

http://cgi.ebay.co.uk/WEBLEY-Pre-Charged-Air-Gun-Rifle-Stirrup-PCP-HAND-PUMP-/230597647196?pt=UK_SportingGoods_Hunting_ShootingSports_ET&hash=item35b0b0db5c

These are the new pumps by Webley and are built sturdy and solid with excellent design. Never cycle more than 80 slow pumps in one go, you must allow the pump to cool for minimum 5 minutes or you will blow the seals. I work to 50 pumps and leave a lot longer than 5 minutes between filling sessions.

In addition, in order to remove the regulator from the paintball tank you may be tempted to get a blow torch on it to loosen the permanent grade loctite (red) applied by the manufacturer.

Do not under any circumstances do this!

It will alter the heat treatment of the metal in the regulator and bottle and may make the bottle unsafe at high pressure.

A better way is to remove the male 1/8 bsp quick release nipple and then use a threaded piece of bar or schedule 80 pipe in that socket. Secure the bottle in a vice with some thick rag to protect it (without crushing it) and then muscle the regulator off.

SAFETY NOTICE:

ALWAYS CHECK THAT THE BOTTLE IS AT ZERO PRESSURE BEFORE REMOVING REGULATOR OR COMPONENTS!

If you do damage the regulator in the process of removing it a replacement can be got on ebay from china for cheap. They sell both 3000 psi and 4500 psi versions but in practice it will be the same regulator with different markings. They will have a 3 to 1 safety ratio anyway.

http://shop.ebay.co.uk/?_from=R40&_trksid=p5197.m570.l1313&_nkw=paintball+regulator&_sacat=See-All-Categories

Hope that helps, and as always be carefull!

RM

[evolvingape]

Hi Everyone,

I have scoured the net for some background resources for what I want to talk about today, and that is material selection for turbine discs. There is much more information in the links provided, I have simply grabbed some relevant parts and reproduced them here to provide structure. I do advise reading through all the links. A summary is provided at the end...

304   = 1.4301
321   = 1.4541 (Titanium stabilised 304)
316L  = 1.4404 (Low Carbon < 0.03%)
316Ti = 1.4571 (Titanium stabilised 316)

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http://www.bssa.org.uk/topics.php?article=71

The presence of titanium to 1.4571 does, however, give some improvements to mechanical strength, especially, at elevated temperatures above about 600 C. and care must therefore be exercised in selecting 1.4404 as a substitute under these conditions.

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http://www.euro-inox.org/pdf/map/Stabilised_LowCarbonAust_EN.pdf

As a conclusion, it can be stated that the use of grade 1.4571 over 1.4404 and 1.4541 over 1.4307 is only technically justified when high temperature strength is a consideration. A summarised comparison between the Ti-stabilised and low carbon stainless steels is presented in the table.

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http://www.askzn.co.za/tech/tech_grade_316.htm

SX 316 Ti, the titanium-stabilised version, is used for its resistance to sensitization during prolonged exposure in the 550 C - 800 C temperature range.

=====

http://www.alleghenytechnologies.com/ludlum/Documents/316ti.pdf

Stress Corrosion Cracking

Austenitic stainless steels are susceptible to stress corrosion cracking (SCC) in halide environments. Although the Type 316, 316L and 316Ti alloys are more resistant to SCC than the 18 Cr-8 Ni alloys, they still are quite susceptible. Conditions that produce SCC are:

(1) Presence of halide ion (generally chloride),
(2) Residual tensile stresses, and
(3) Temperature in excess of about 140°F (60°C).

Stresses result from cold deformation or thermal cycles during welding. Annealing or stress relieving heat treatments may be effective in reducing stresses, thereby reducing sensitivity to halide SCC. Although the stabilised Type 316Ti and low carbon grades offer no advantage as regards SCC resistance, they are better choices for service in the stress relieved condition in environments which might cause intergranular corrosion.

FABRICATION AND WELDING

Fabrication

The austenitic stainless steels, including the Type 316Ti alloy, are routinely fabricated into a variety of shapes ranging from the very simple to very complex. These alloys are blanked, pierced, and formed on equipment essentially the same as used for carbon steel. The excellent ductility of the austenitic alloys allows them to be readily formed by bending, stretching, deep drawing and spinning. However, because of their greater strength and work hardenability, the power requirements for the austenitic grades during forming operations are considerably greater than for carbon steels. Attention to lubrication during forming of the austenitic alloys is essential to accommodate the high strength and galling tendency of these alloys.

Annealing

The austenitic stainless steels are provided in the millannealed condition ready for use. Heat treatment may be necessary during or after fabrication to remove the effects of cold forming or to dissolve precipitated chromium carbides resulting from thermal exposures. For the Type 316Ti alloy the solution anneal is accomplished by heating in the 1900 - 2150°F (1040 - 1175°C) temperature range followed by air cooling or a water quench, depending on section thickness. For maximum resistance to sensitization, Type 316Ti should be given a stabilizing heat treatment at 1550-1650°F (845-900°C) to precipitate titanium carbides and prevent the precipitation of chromium carbides during lower temperature exposure. Type 316Ti cannot be hardened by heat treatment.

Welding

The austenitic stainless steels are considered the most weldable of the stainless steels. They are routinely joined by all fusion and resistance welding processes. Two important considerations for weld joints in these alloys are (1) avoidance of solidification cracking, and (2) preservation of corrosion resistance of the weld and heataffected zones. Type 316Ti stainless steel often is welded autogenously. If filler metal must be used for welding Type 316Ti, it is advisable to utilize the low carbon Types 316L or E318 filler metals. Contamination of the weld region with copper or zinc should be avoided, since these elements can form low melting point compounds, which in turn can create weld cracking.

Stabilized austenitic stainless steels, such as Type 316Ti, can be attacked by intergranular corrosion under certain special conditions after welding. One such condition results in what is known as knifeline attack This manifests itself as a very narrow band of severe corrosion adjacent to a weld. This occurs when the metal adjacent to the weld is heated to a high temperature (greater than 2100°F) so that the titanium carbides are dissolved, and then subsequently exposed to temperatures in the sensitizing region (800°–C - 1500°F; 425°C - 815°C). At these temperatures, the rate of formation of titanium carbides is sluggish, and the free carbon reacts with chromium to form grain boundary carbides in the heat affected zone.

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http://en.wikipedia.org/wiki/Corrosion

Weld Decay and Knifeline Attack

Stainless steel can pose special corrosion challenges, since its passivating behavior relies on the presence of a minor alloying component (Chromium, typically only 18%). Due to the elevated temperatures of welding or during improper heat treatment, chromium carbides can form in the grain boundaries of stainless alloys. This chemical reaction robs the material of chromium in the zone near the grain boundary, making those areas much less resistant to corrosion. This creates a galvanic couple with the well-protected alloy nearby, which leads to weld decay (corrosion of the grain boundaries near welds) in highly corrosive environments. Special alloys, either with low carbon content or with added carbon "getters" such as titanium and niobium (in types 321 and 347, respectively), can prevent this effect, but the latter require special heat treatment after welding to prevent the similar phenomenon of knifeline attack. As its name applies, this is limited to a small zone, often only a few micrometres across, which causes it to proceed more rapidly. This zone is very near the weld, making it even less noticeable.

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Summary:

Ok, a lot to take in

The two main grades we are looking at here are 316L and 316 Ti.

316L is going to be suitable for both the HELP and the HELT devices. The reason I say this is that I do not expect the operating temperature of either to exceed 400 C. Should prototyping prove a continuous temperature greater than 400 C then 316L is not going to be suitable for any length of time. This is because at temperatures above 400 C 316L will rapidly lose its strength properties, and as the turbine discs will be rotating at high speed any significant loss in strength could cause the blades to critically fail from the tensile stresses of centrifugal force.

This problem would be further increased by the HELP and HELT being used in Closed System Crossover mode and the electrolysis function would weaken the blades and cause corrosion. The HELP and HELT will have a maximum operating life, measured in hours run, before the entire disc stack and shaft must be completely replaced with new components.

The RotoMax is a different animal altogether and is not enduring the effects of CSC. I expect the RotoMax will probably have to deal with a constant operating temperature in the range 400 - 800 C. This means that 316 Ti would be a much better choice than 316L as it has a far higher strength in this temperature range. Should normal operating temperature exceed 800 C then there is the potential option of using ceramic carbon composite as already talked about. As there is no CSC occurring, all components can be made of metal to withstand the high rotational stresses and temperatures.

The discs are probably going to be laser cut, which means a localised rapid high temperature increase on the resultant edges (similar to welding). The metal must be carefully de-burred and then stress relieved via suitable heat treatment process before being spun up in the turbine, or the discs might tear themselves apart.

In addition, it might pay dividends to run the RotoMax when powering down purely on a constant flow of cold water. This would bring the disc rotors that have been operating in the 400 - 800 C range for extended periods of time rapidly down to ambient temperature and mimic the stress relieving process.

The last point is hydrogen embrittlement...

http://en.wikipedia.org/wiki/Hydrogen_embrittlement

The mechanism starts with lone hydrogen atoms diffusing through the metal. At high temperatures, the elevated solubility of hydrogen allows hydrogen to diffuse into the metal (or the hydrogen can diffuse in at a low temperature, assisted by a concentration gradient). When these hydrogen atoms recombine in minuscule voids of the metal matrix to form hydrogen molecules, they create pressure from inside the cavity they are in. This pressure can increase to levels where the metal has reduced ductility and tensile strength up to the point where it cracks open (hydrogen induced cracking, or HIC).

High-strength and low-alloy steels, nickel and titanium alloys are most susceptible. Austempered iron is also susceptible.[citation needed] Steel with an ultimate tensile strength of less than 1000 MPa or hardness of less than 30 HRC are not generally considered susceptible to hydrogen embrittlement. Jewett et al.[1] reports the results of tensile tests carried out on several structural metals under high-pressure molecular hydrogen environment.

These tests have shown that austenitic stainless steels, aluminum (including alloys), copper (including alloys, e.g. beryllium copper) are not susceptible to hydrogen embrittlement along with few other metals.[2] For example of a severe embrittlement measured by Jewett, the elongation at failure of 17-4PH precipitation hardened stainless steel was measured to drop from 17% to only 1.7% when smooth specimens were exposed to high-pressure hydrogen.

I have highlighted the part in bold that states that austenitic stainless steels are not susceptible to hydrogen embrittlement, however I personally do not know if this is true. Prototyping and people who know more about this subject than me are going to be required to resolve the issue.

As an example of how complicated hydrogen embrittlement gets:

http://www.msm.cam.ac.uk/phase-trans/2006/hydrogen.Yamasaki.PRA.2006.pdf

The important thing to remember about all of this is that we are attempting proof of theory of these concepts. If the theory is sound, and we get results that we can work with, then the material development will come with the investment of interest in these technologies. The off the shelf materials may be suitable in their own right, but will most certainly be able to be improved with directed investment over time.

Hope this is helpfull to you all

RM