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  1. metalman8357

    How would I get this Custom Cable Manufactured for a Prototype?

    I need to have a cable manufactured for a prototype that I am working on and I'm at a loss as to where to go to have something like this made. I've contacted a few places that specialize in custom cable manufacturing but they all have 500ft+ minimum lengths and I only need about 20 feet made...
  2. metalman8357

    Tapping into Power from Wall Outlet Receptacle?

    Hello All, I am working on a product that will be an actively powered face plate for a wall outlet receptacle. Basically the socket will provide power for my faceplate and I need to tap into the power of the outlet. There is a company that makes an active face plate () and they use a patented...
  3. metalman8357

    What is the bonding mechanism in Soldering and Brazing?

    I think this is a pretty basic question but I'm curious about the type of bond that is formed in soldering and brazing processes. Take a tin/lead solder onto copper for example; does a metallurgical bond form between the tin/lead solder alloy and the copper even though the copper is not melted...
  4. metalman8357

    Aluminum Alloy with a Pliable Transition Zone Between Solid and Liquid?

    Hi All, I'm working on a project where our goal is to design an extrusion head for aluminum wire. Basically the goal is to feed 0.035" wire through a tapered ceramic nozzle that is wound in a water cooled copper induction coil so that when it exits the nozzle (tip diameter 0.015") it will be...
  5. metalman8357

    Alternate method to determine position in two axis besides using linear encoders?

    Hello, I'm working on a project where I will need to determine and record the XY position of a stylus over an 18" x 36" table. The stylus will be mounted on a gantry to move freely in the Y axis, and will also be mounted on a slide on the gantry beam to move freely in the X axis. I want the...
  6. metalman8357

    Calculating Transformer Core Area

    Hello, My application requires the use of a custom transformer and I want to calculate the theoretical minimum core cross sectional area that will be needed in order to achieve my power output ratings. The input voltage will be standard 120VAC and the output will be 5VAC at 500mA. I would like...
  7. metalman8357

    Power Supply Smoothing without Capacitor?

    I posed this question to some of my electronics engineering colleagues and they couldn't really offer a good answer. Can anyone theorize what might be a possible way for smoothing a rectified AC waveform to DC without the use a capacitor?? Basically how can this be achieved with the use of...
  8. metalman8357

    Requirements for an AC Power Adapter

    Hello, I'm a mechanical design engineer by trade and I've started working on a side project for developing a special 120V AC to 5V DC adapter. Without going into too much detail on the design, I was wondering where I should be looking in regards to the regulatory requirements that this product...
  9. metalman8357

    Carburizing Question

    Hey guys, I've got a quick question about carburizing and I can't seem to find a good answer in my references. I'm running a carburizing process on a custom alloy with similar chemistry to 8620 at 0.95% constant carbon potential and 1700F for 17.3 hours. The part is a rectangular bar measuring...
  10. metalman8357

    Post Plating Bake Delay -- Hydrogen Embrittlement

    Hello all, I was wondering if anyone had any experience with how much of an effect the delay time between electroplating and baking of hardened components has on hydrogen embrittlement? We have very expensive and critical components that we are electroplating on top of a carburized surface and...
  11. metalman8357

    Gas Carburizing Uneven Case Hardness

    Hello all, I am case hardenening a large part ( 12"D x 3'L cylinder, HSLA steel) and I am seeing strange results on the test bars that are treated along with the part. Just to back up a little the furnace is new, and I have been playing around with carbon potential and process time in order to...
  12. metalman8357

    Sand Grit Seperation System

    Hi All, I've been tasked with creating a system for seperating out the two different grit sands we use in our media blast booth. We currently use 36 grit and 80 grit, and we encounter issues when these two grits are allowed to mix. For example, we could have in our large gravity feed hopper...
  13. metalman8357

    MT Indications after Stress Relief

    Welding plain carbon steel with the FCAW process. The component is a 12' diameter x 2" wide ring fillet welded on both sides to the face of a large plate. We use dry powder to MT the welds before stress relief and then we use wet MT fluorescence after stress relief. We stress relief at 1130F for...
  14. metalman8357

    Glass FRP in Salt Water

    Hi All, I recently conducted testing with 1/8" fiberglass laminates to determine the durability of this material in sea water. We first conducted tensile tests at room temperature on the material as a control, and then immersed some samples in salt water for 1000 hr. We found that the samples...
  15. metalman8357

    Peltier Tile Calculation

    Hi all, I'm working on a prototype for a customer that might incorporate the use of thermoelectrics for power recycling. I would like to calculate the voltage generation for using a square tile (0.5" x 0.5") with a constant temperature difference of 35 deg. F. I would probably just use an off...
  16. metalman8357

    Annealing 316 During Heat Treatment

    Hi all, Just a quick question. I have a component that is friction stir welded 316SS and 1060 plain carbon steel. We'd like to Austemper the 1060 component, but I'm wondering if this will have any affect on the hardness/corrosion resistant properties of the 316 part? Induction hardening is not...
  17. metalman8357

    Painting Stainless Steel and Corrosion

    Over the years I have seen some stainless steel part manufactures specifically state to not paint stainless steel, but I'm trying to figure out why this might be an issue? Can anyone suggest a possible mechanism or example in the literature for how paint might accelerate or be harmful to the...
  18. metalman8357

    Sand Gradation

    Hi all, Just a few quick questions about sand gradation and nomenclature. When a manufacturer says that they supply a mesh 16-20 sand, what does this mean exactly? Is there a standard or some type of requirement that they must meet during sieve analysis to call it this sand i.e. 95% of...
  19. metalman8357

    Restoring Ductility to Zamak 3? (Zinc-Al alloy)

    Hi all, I have parts that were die-cast from Zamak 3. The parts are meant to undergo slight bending and plastic deformation in service. Our new lot, however, undergoes cracking during this process which indicates a decrease in ductility. The chemistry shows that the parts are within the...
  20. metalman8357

    Need Material for Hardened Pins

    Hi all, I'm working on a project to spec material for some 2" long 0.162" diameter hardened pins. The material must be in the form of drawing wire since there is a heading process to form a 5/16" diameter head (imagine a nail without a sharp point). The pins are then through hardened to...

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