I tried posting this earlier today, but it didn't seem tp go through, so I'll try again.
We are re-purposing an old transformer to use as a magneto magnetizer.
We started with a transformer that has a two piece armature. The bottom was one piece, in the shape of an I, 1.75 in thick by 3.5 in wide, made of laminations approx .015 in thick. The rest of the armature was in the shape of an E , with the two outer legs measuring 1.75 in X 3.5 in, and the center leg being 3.5 in X 3.5 in.
There were three coils on the center leg, with approx 400 turns total of 6 ga CU wire. At 200 amps, that will give 80,000 amp turns.
Our plan is to wire them in series, and leave them on the center leg.
We will cut one leg off, surface grind the outside edge of it, and the outside edge of the remaining leg, and put them back to back to get another 3.5 X 3.5 leg, with what now becomes a flat bottom U.
The bottom of the U will be ground, as will one side of the I piece, and the U will be set on it to get a 3.5 X 3.5 U.
When we dis-assembled the transformer, the bottom I piece was held on by some side straps, and there were some iron shims between it and the ends of the E legs, along with some sort of metal filled plastic like substance, which looked as though it was a paste when applied, and hardened after the transformer was assembled. Is there something used in magnetics, which transfers flux, that is analogous to heat sink compound used in electronics? We were thinking about using epoxy filled with ground ferrite to bind the pieces together, but didn't know if that would degrade the flux transfer more than just the ground surfaces in contact with each other.
I heard some place that one pole of a magnet is slightly stronger than the other. Since the coils will be installed on one of the legs of the U, will the flux on that pole be stronger, and thus bebetter used to magnetize the weaker pole of the magnet being magnetized?
Does a laminated core perform better with a direct current magnet than a solid core?
I will have more questions as this progresses, so thank you in advance for your help and patience.