Serious HES derivative project proposal

[Cadman]

The fiberglass resin works well and pops right out of the waxed PLA mold.

The best casting so far has a density of 3.66 g/cm³, including the resin. This is with the IRON100 powder and 6mm thickness.
It's totally non-conductive so I'll keep lowering the resin ratio as far as practical. Right now it's 50/50.

[kolbacict]

I was checking out by own experiment.
The current of generator rotor don't change,not increase,nor decrease  if change RPM or value of load. From the load current, only the load on the motor changes.

[SolarLab]

Laminate experiments continue. Up 'til now I've only managed to keep from reducing the density too much below the 2.52 g/cm³ apparent density of the loose powder.

I may have found the ideal composite powder for DIY though, ATOMET EM-1. If I can purchase small quantities and also figure out an economical way to compress it to about 420 MPa. That pressure would give it a density about 6.8 g/cm³ which is better than ferrite.

Its most attractive feature for DIY is that it cures in 30 minutes at 200 C. No expensive kiln needed.

Hi Cadman,

Great information/discovery - THANKS X 1K...

Finally found some time to revisit SMC's. ATOMET EM-1 by QMC (Quebec Metal Products) Rio Tinto
is quite exciting to say the least; plus it's a Canadian company. Their web site contains so much
information and documentation it will take a while to digest but it's the best I've ran accross so far.

Haven't checked the pricing and availability yet, that's still a TO-DO. Compression might be easier
than first anticipated by just using an inner mold (3D Printed as you did) with AL bar side supports
and AL bolted Top and Bottom plates. Lots of ideas to sort through.

LinGen design is easy however. Thought about using "Machinable Wax" as a re-usable Mold but will
have to check the compression limits, etc. Many advantages if it works.

Anyway, thanks again. Take care and good luck!

SL

[Jimboot]

The fiberglass resin works well and pops right out of the waxed PLA mold.

The best casting so far has a density of 3.66 g/cm³, including the resin. This is with the IRON100 powder and 6mm thickness.
It's totally non-conductive so I'll keep lowering the resin ratio as far as practical. Right now it's 50/50.

Thanks Cadman for the update. I'm still fabricating when I can work is keeping me busy. Your updates are helpful and appreciated.

[Cadman]

Hi SL,

THANKS X 1K right back at ya..

I just happened to have a casting and mold in front of me when I saw your post and it gave me an idea.

You know, this iron/resin casting is pretty strong stuff, even at 50/50 ratio, and it's machinable.

I'm going to print PLA molds for a punch and die set, cast a pair, and attach a thick mild steel base to each. Grade 8 bolts & nuts to apply the pressure.

I think there's a good chance this will work since the part I'm compressing is small and only a few mm thick.


Hey Jimboot,

I'm in the same boat. 60+ hrs every week is a PITA.