Thursday, 29/06/2023, 10:09

I left this project log written in a text file and I forgot what I was supposed to originally write on it, but I think it is worth posting.

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So, I was looking at some youtube videos about magnetic gears just for procrastination porpuses and to my surprise, 3D printed gears are around 82% efficient.
Not 90%, as I would liked, but still a quite of a number for a bunch of plastic poorly sticked together.

Welp, maybe I could not be as obsessed with precision and efficiency with the use of laser cutting stores, because I kinda feel like if I were to actually call a random laser cutting store, they would probably not be as concerned with precision as I would.

Also, this recent video from James bruton may be useful, since he does teach a bit on how to improvise good precision:

However, I'm finding a little bit hard to come up with the right choice of words to find high precision tutorials for DIY projects.

Also, I just found this tutorial that I think it might be useful:

It is a video tutorial on how to use DVD/floppy drivers to make a DIY high precision 3D printer.
And I'm not kidding on the "high precision" aspects, the DVD/CD readers and engravers need to have microscopic precision capabilities in order to precisely read the information present on CD's/DVD's, so a 3D printer or even CNC machien using these would be extremely precise.

It might be relevant to reach out for these 3D printed high precision gauges... >.>

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Also, a couple of things that I need to add about the Hydrogen Fuel cell:

Bruh, to be honest, it is not a "couple", it is a lot... If I don't literally copy paste the entire ChatGPT conversation, I don't really know how to summarize everything in a meaningful manner that can be compreensive without letting essential details behind.

It is like trying to explain how a combustion engine works, yeah, I could tell you how it work, but it would be useful if I told you why I choose to do a combustion engine the way I did, so you can have a better comprehension of how to do it.

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1- Catalyst ink deposition:
There a couple of methods used for depositing/binding/adding the catalyst and other reactants to the electrodes, and I say this because mixing pure iron and/or nickel to a carbon substrate and burn it wouldn't be beneficial, in fact, it would make the fine powder of iron-nickel chemically react to carbon in order to make Steel-nickel alloy (steel is iron with carbon).

So, I would need to make the carbon sponge electrodes with sodium silicate/potassium silicate and then add the powder later.

The powder with the catalysts and other mateirals would be dispersed/dissolved in acetone and/or Ethanol (and others, such as water, but it could oxidize the iron/nickel) and then sprayed on the electrodes, like a ink, which would just evaporate and leave the essentials behind.

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2- Additive enhancer on the electrodes:

So, I did say in the previous project log that one could add some extra things to the membrane and electrodes so its efficiency/performance is increased.
I don't know if professionally/industrially made hydrogen fuel cell employs all the little bits and so on, but since these have properly made materials (such as Nafion, platinum and carbon black/vulcan), I think it would be useful to add to this specific DIY situation.

2.1: Conductive Carbon additives:
Yeah, the homemade graphene that I don't shut up about, carbon nanotubes and/or carbon fibers.

2.2: Binders:
Common binder materials include Nafion, polyvinylidene fluoride (PVDF), or polytetrafluoroethylene (PTFE). Binders aid in maintaining the structural integrity of the electrode and improving catalyst adhesion.

2.3: Surfactants or dispersing agents:
Triton X-100: Triton X-100 is a nonionic surfactant commonly used in ink formulations. It can improve the dispersibility and stability of the catalyst particles.
Sodium dodecyl sulfate (SDS): SDS is an anionic surfactant that can be used to disperse catalyst particles in aqueous-based inks.

2.4: Porosity-enhancing agents:
Certain materials can be incorporated into the catalyst ink to introduce porosity to the electrode structure. For example, sacrificial pore-forming agents like polyethylene glycol (PEG) can be mixed with the ink. During the electrode fabrication process, these agents can be burned off or dissolved, leaving behind porous structures that enhance reactant diffusion and increase the electrode's active surface area.
Polyethylene glycol (PEG): PEG is a commonly used sacrificial pore-forming agent. It is added to the ink in solid or dissolved form and subsequently burned off or dissolved during the heat treatment or washing steps of the electrode fabrication process.
Besides PEG, other sacrificial polymers can be used as pore-forming agents. Examples include polyvinyl alcohol (PVA) and cellulose derivatives. These polymers can be incorporated into the catalyst ink and subsequently removed by thermal decomposition or solvent extraction.

2.5: Stabilizers:
Cerium salts:
Cerium salts, such as cerium nitrate or cerium oxide nanoparticles, can be used as stabilizers to mitigate catalyst degradation in certain fuel cell systems.
Ruthenium-based compounds: Ruthenium-based compounds, such as ruthenium dioxide (RuO2), can act as stabilizers for certain catalyst materials.
Inorganic particles: Inorganic particles, such as silica particles or alumina particles, can be used as templates for creating pores in the electrode structure. These particles can be mixed with the catalyst ink, and after the electrode fabrication process, they can be etched or dissolved, leaving behind pores.

Cerium salts: Cerium salts can be used as stabilizers in certain fuel cell systems. Common examples include cerium nitrate (Ce(NO3)3) and cerium sulfate (Ce(SO4)2). These salts can provide protection against corrosion or degradation of catalyst materials.

Cerium oxide-based catalysts: While cerium oxide (CeO2) itself is not a salt, it is an inorganic compound that can act as a catalyst or catalyst support in fuel cells. Cerium oxide-based catalysts can exhibit enhanced oxygen storage and release properties, which can be beneficial in certain fuel cell systems.

Cerium-based mixed metal oxides: Cerium can be combined with other metal elements to form mixed metal oxides, which can be used as catalysts or catalyst supports. For example, cerium-zirconium oxide (Ce-Zr-O) or cerium-titanium oxide (Ce-Ti-O) are commonly used in fuel cell applications, especially in solid oxide fuel cells (SOFCs).

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3- Additive enhancers for the membrane:

ChatGPT explains it throghouly, but just to remember how the membrane would be made:

Each DIY alkaline eletrolyte membrane will be made using 10g of PVA (polyvinyl alcohol) 5g of PVP (polyvinyl pyrrolidone) mixed with water, molded into shape until dry with no bubbles, prensed between two glass plates for optimal surface. Then 20ml of glutaraldeyde (2%), 10 drops of HCL (Chloridric Acid) and 40ml of pure acetone will be mixed in a crosslink solution in which the membrane will be submerged for 40 minutes for the reaction to occur and transform the membrane in some hydrogel looking material. Lastly, a solution made with 50 ml of water, 8.6g of KOH where the membrane will bath is then heated up to 60ºC for 3 hours until the membrane gets a browish colour. Meaning it is ready to be used.

PS: ChatGPT said that it would be recommended to maintain the membrane materials at maximum 100ºC of temperature and pressures at between 1 to 6 atmospheres/1 to 6 bars. Were the oxygen side is normally at ambient pressure.

"To incorporate enhancers such as graphene, carbon nanotubes, ionic liquids, conductive polymers, and plasticizers into the alkaline electrolyte membrane, it would be ideal to introduce them at specific stages of the membrane production process. Here's a suggested approach based on the steps you provided:

PVA and PVP Mixing and Formation:

Graphene and/or carbon nanotubes can be added during the mixing of PVA and PVP. These nanomaterials can be dispersed in the water solution before combining them with PVA and PVP. This step ensures uniform distribution of the nanomaterials within the membrane.
Crosslink Solution:

Ionic liquids, such as EMIM TFSI, can be incorporated into the crosslink solution. Mix the appropriate amount of ionic liquid with glutaraldehyde, HCl, and acetone to form the crosslink solution. The membrane should be submerged in this solution during the crosslinking process.

KOH Bath:

Conductive polymers and plasticizers can be introduced during the KOH bath step. Prior to immersing the membrane in the KOH solution, add the conductive polymers (e.g., polyaniline, polypyrrole) and plasticizers (e.g., glycerol) to the water-KOH solution. This allows for the absorption of these enhancers by the membrane during the final treatment.
By incorporating these enhancers at the appropriate stages, you can maximize their dispersion and potential benefits within the alkaline electrolyte membrane. However, it's important to note that the specific concentrations and amounts of these enhancers would require optimization through experimentation to achieve the desired performance improvements.

When it comes to finding readily available and DIY-capable alternatives for ionic liquids, it can be challenging as these substances often require specific synthesis or specialized components. However, there are some options you can consider:

Homemade Ionic Liquids: It is possible to synthesize some ionic liquids using common chemicals, but the process can be complex and may require advanced chemistry knowledge. Here's a simplified example:

One example is the synthesis of a simple imidazolium-based ionic liquid. You can mix 1-methylimidazole (available from chemical suppliers) with an alkyl halide, such as bromoethane or iodomethane (available from hardware stores or chemical suppliers), in the presence of a base like sodium hydroxide or potassium hydroxide. This can result in the formation of an imidazolium-based ionic liquid.
It's crucial to note that working with chemicals and performing synthesis reactions requires proper safety precautions, equipment, and knowledge. Therefore, if you're not experienced in this area, it's recommended to consult with a chemist or obtain pre-made ionic liquids from specialized suppliers.

Alternatives to Ionic Liquids: If obtaining or synthesizing ionic liquids is not feasible, there are alternative additives that can enhance membrane properties. Some possibilities include:

Conductive salts: Certain salts like sodium bicarbonate or potassium carbonate can improve the ionic conductivity of the membrane when added in small amounts.

Conductive polymers: Polymers like polyaniline or polypyrrole, mentioned earlier, can enhance conductivity and ion transport in the membrane.

Plasticizers: Glycerol is a commonly used plasticizer that can improve the flexibility and mechanical properties of the membrane.

These alternatives may not provide the exact same performance enhancements as ionic liquids, but they can still contribute to improving the efficiency and properties of the alkaline electrolyte membrane.

Remember to consider safety precautions, experiment carefully, and adjust the concentrations and amounts of these additives to achieve the desired performance while ensuring the overall stability and functionality of the membrane."

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4- Other methods for catalyst deposition:

Catalyst ink deposition (already explained):
This method involves preparing a catalyst ink by dispersing the catalyst material (e.g., platinum, nickel) in a suitable solvent along with a binder material (such as Nafion or polyvinylidene fluoride, PVDF). The ink is then applied to the carbon electrode surface using techniques like brush coating, spray coating, or screen printing. After deposition, the solvent is evaporated, leaving behind a catalyst layer adhered to the carbon substrate.

Inkjet printing:
Inkjet printing allows precise and localized deposition of catalyst ink onto the carbon electrode substrate. The catalyst ink, similar to the catalyst ink deposition method mentioned earlier, is loaded into an inkjet printer, and droplets are selectively deposited onto the substrate. Inkjet printing offers high resolution and flexibility in catalyst patterning.

Electrophoretic deposition:
In this technique, a suspension of catalyst particles in a solvent is subjected to an electric field. The charged catalyst particles migrate and deposit onto the oppositely charged carbon electrode, forming a catalyst layer. Electrophoretic deposition offers good control over catalyst loading and distribution.

Physical vapor deposition (PVD):
PVD techniques, such as sputtering or evaporation, involve depositing catalyst materials onto the carbon electrode substrate in a vacuum chamber. The catalyst material is vaporized and then condenses onto the substrate, forming a thin catalyst layer. PVD techniques offer precise control over catalyst thickness and composition.

Chemical vapor deposition (CVD):
CVD involves the chemical reaction of precursor gases in the presence of the carbon electrode substrate to deposit a catalyst layer. The precursor gases containing the desired catalyst material are introduced into a reactor, where they decompose and deposit the catalyst onto the substrate. CVD can provide conformal and controlled catalyst coatings.

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4.1:
Well, I do think that the Sputtering may be simpler and cheaper to make/build/use, ironically enough, fine iron/nickel powder that is useful for chemical reactions are expensive as f8ck.
But nickel, iron and other material plates are really cheap... For electroplating. For sputtering is expensive as hell. I mean, for *proper* sputtering.

If you don't know what sputtering is: Basically, you put a material target in a vacuum with a metal plate of your choice, then you apply plasma to this plate and it covers the material target.
You can literally make one with microwave parts or simple electrodes for welding.

The problem is that since Vaccum pumps are expensive and the maintenence of proper vaccuum is kinda hard to do in a DIY manner, I believe you you would need just not a Co2 scrubber, but also a oxygen scrubber, because the oxygen would probably react with the iron and the nickel to form an oxide layer the same way it would also react with the carbon.
Of course, assuming that this would be enough of a problem, after all, in a closed chamber, eventually both would react with the present oxygen/carbon and cover the reacted layers with unreacted layers. Like a cake...?

The thing is, our atmosphere is 78% nitrogen, 21%  oxygen, 2% water vapor and 0.98% carbon dioxide, argon gas and others. So you wouldn't need vacuum if you were to use innert gases such as nitrogen and argon... *I think*...

... Well, I thought wrong, because nitrogen is definitely not an inert gas, only argon is, so I would need both a nitrogen, oxygen and co2 scrubber, lol. And nitrogen is definitely not easy to get rid of, which means I would need to either find argon gas sources (expensive), helium gas sources (even more expensive) or a vacuum pump (less expensive). lol

However, there could be something useful in this: silicon nitride is an isolator.
Meaning that I could sputter this material on windings or laminations in order to make isolating layers even thinner than enamelling.

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4.2:

Welp... I can just go to electroplating, the electrodes need to be efficiently conductive anyway...

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4.3: Enhancing materials for electroplating:

"In electroplating for catalyst adhesion or deposition on electrodes, various types of enhancers or additives can be used to improve the plating process and enhance the quality of the catalyst layer. These enhancers can serve different purposes such as improving the adhesion, controlling the deposition rate, enhancing the uniformity, or modifying the properties of the deposited catalyst. Here are some specific enhancers commonly used in electroplating for catalyst deposition:

Surfactants:
Nonionic surfactants: Examples include Triton X-100, Pluronic, or Tween series.
Anionic surfactants: Examples include sodium dodecyl sulfate (SDS) or sodium lauryl sulfate (SLS).
Cationic surfactants: Examples include cetyltrimethylammonium bromide (CTAB) or cetylpyridinium chloride (CPC).
Brighteners:

Levelling agents:
Examples include saccharin, coumarin, or p-phenylenediamine (PPD).
Sulfur-containing compounds: Examples include thiourea or thiocyanates.

Additives for adhesion promotion:
Organic acids:
Examples include citric acid, tartaric acid, or malonic acid.

Complexing agents:
Examples include EDTA, gluconate, or oxalate.

Wetting agents:
Examples include ethoxylated alcohols or alkylphenol ethoxylates.

Grain refiners:
Metal or alloy additives: Examples include grain-refining agents like bismuth, antimony, or cobalt.

pH adjusters or buffers:
Acids: Examples include sulfuric acid or hydrochloric acid.
Bases: Examples include sodium hydroxide or ammonium hydroxide.
It's important to note that the specific enhancers or additives to be used will depend on the plating bath composition, the desired properties of the catalyst layer, and the specific fuel cell system requirements. The concentration and combination of enhancers will also vary depending on the specific application.

For optimal results, it is recommended to consult scientific literature, research papers, or seek guidance from experts in the field who have experience with electroplating for catalyst deposition. They can provide specific recommendations and insights based on your system requirements and the catalyst material you are working with.

Levelers, also known as leveling agents, are a type of enhancer commonly used in electroplating processes to improve the surface smoothness and uniformity of the deposited metal layer. They help to minimize or eliminate uneven deposition, known as "dendritic growth," which can result in rough or non-uniform coatings. Levelers work by slowing down the deposition rate on high-current density areas, allowing more time for the metal ions to distribute evenly across the electrode surface.

Specific examples of levelers used in electroplating processes include:

Organic levelers:
Saccharin: Saccharin is a common organic leveler used in various electroplating applications. It can help promote a smooth and uniform metal deposition by preferentially adsorbing on high-current density areas, reducing their growth rate.
Coumarin: Coumarin derivatives, such as 2,7-dihydroxycoumarin, can act as levelers in certain electroplating processes. They exhibit surface-active properties and preferential adsorption on high-current density regions.
p-Phenylenediamine (PPD): PPD is often used as a leveling agent in electroplating baths. It forms a surface film that reduces the growth rate of metal deposits on the cathode surface.
Other levelers:

Sulfur-containing compounds: Some sulfur-containing compounds, such as thiourea or thiocyanates, can act as levelers by preferentially adsorbing on high-current density areas and slowing down metal deposition.
The selection and concentration of levelers will depend on the specific electroplating process, the metal being deposited, and the desired surface finish. It is important to note that the effectiveness of levelers can vary depending on the specific system and conditions. Experimentation and optimization may be required to achieve the desired leveling effect.

Consulting scientific literature, research papers, or seeking guidance from experts in the field with expertise in electroplating and levelers can provide specific recommendations and insights tailored to your application."

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All of this sounds cool and all, but I feel like these enhancers are expensive as heck...

I'm going to slep right now, but tomorrow I will search it throghouly.

And bruh, an annoying thing for me in ChatGPT is that it doesn't allow me to fuse different chats together. So I have dozens upon dozens of chats with closely related subjects or subjects that already were forgotten in the walls of text that it is basically poor use of space.

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Edit¹:

I just copy pasted all information of every chat to a single one, including project logs.

Then I copy pasted to a microsoft document that instantly crashed and took 10 minutes to load the entire document.

It gave around 1000 pages. Like, bruh.

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Also, I did try to check out how to make PEEK plastic, which is a high performance plastic that is so strong that it can easily surpass metals in almost all aspects.

The problem is that a single kilogram of PEEK filament plastic for 3D print costs 6000 reais (1200 dollars).
Also, it needs benzene to be produced, if you don't know, benzene is cancerous and toxic, so yeah...

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"Producing high-performance polymers like polyether ether ketone (PEEK) or sulfonated polyetheretherketone (SPEEK) typically requires specialized equipment and expertise. It is a complex process that involves several steps and requires precise control over reaction conditions. Consequently, it is challenging to produce these polymers in a DIY configuration without access to a well-equipped laboratory and knowledge of polymer synthesis.

Here's a general overview of the steps involved in synthesizing PEEK or SPEEK:

"Raw materials: The basic starting materials for PEEK synthesis are 4,4'-difluorobenzophenone (DFB) and 4,4'-difluorodiphenyl sulfone (DFDPS). Additional chemicals are required for SPEEK synthesis, such as a sulfonating agent like sulfuric acid.

Polymerization: The synthesis of PEEK involves a step called nucleophilic aromatic substitution (SNAr), where DFB and DFDPS react together in the presence of a base, such as potassium carbonate, and a high-boiling solvent like N-methylpyrrolidone (NMP). This process results in the formation of PEEK.

Sulfonation (for SPEEK): If you specifically want to produce SPEEK, an additional step is required to introduce sulfonic acid groups. This is typically achieved by treating the PEEK polymer with a sulfonating agent, such as concentrated sulfuric acid, at elevated temperatures. The extent of sulfonation can be controlled by adjusting reaction conditions.

Polymer purification: After the synthesis, the polymer needs to be purified to remove any unreacted monomers, byproducts, or impurities. This purification process usually involves washing the polymer with solvents, such as methanol or water, followed by drying.

Polymer shaping: Once you have the purified PEEK or SPEEK polymer, you can shape it into the desired form. This can be achieved through various methods like compression molding, extrusion, or injection molding, depending on the specific application and equipment available.

It's important to note that the synthesis of PEEK and SPEEK involves potentially hazardous chemicals and requires knowledge of handling them safely. The reaction conditions, including temperature, pressure, and time, need to be carefully controlled to obtain the desired polymer properties. Without access to proper equipment, expertise, and safety protocols, attempting to synthesize PEEK or SPEEK in a DIY setting can be challenging and potentially dangerous.

If you are interested in obtaining PEEK or SPEEK for a specific application, it is recommended to source these materials from reputable suppliers who specialize in manufacturing high-performance polymers.

I understand your interest in acquiring the basic materials necessary for the synthesis of PEEK or SPEEK. However, it's important to note that the synthesis of these materials requires specialized chemicals and processes that are not readily available in common daily products or easily accessible to non-specialized individuals. Some of the chemicals involved can be hazardous, and their handling requires expertise and appropriate safety measures.

To obtain 4,4'-difluorobenzophenone (DFB) and 4,4'-difluorodiphenyl sulfone (DFDPS), you would typically need to synthesize them from precursor compounds or source them from specialized suppliers. The synthesis of these materials involves multiple steps and often requires specialized equipment and controlled conditions. I'll provide a general overview of the steps involved, but keep in mind that these processes can be complex and potentially hazardous. It is strongly recommended to consult with experts or professionals in the field before attempting any synthesis.

Synthesis of 4,4'-difluorobenzophenone (DFB):

Start with benzophenone: Benzophenone is a common starting material in the synthesis of DFB. It can be obtained from chemical suppliers or synthesized by various methods, such as Friedel-Crafts acylation of benzene with benzoyl chloride in the presence of a Lewis acid catalyst, like aluminum chloride.

Fluorination: Once you have benzophenone, the next step involves introducing fluorine atoms at the desired positions. This typically requires specialized fluorination reagents, such as hydrogen fluoride (HF) or elemental fluorine (F2), and careful control of reaction conditions. The fluorination process can be challenging and potentially hazardous due to the reactivity of fluorine.

Synthesis of 4,4'-difluorodiphenyl sulfone (DFDPS):

Start with diphenyl sulfone: Diphenyl sulfone is a precursor for DFDPS synthesis and can be obtained from chemical suppliers or synthesized by the reaction of phenol with sulfuric acid, followed by oxidation with a strong oxidizing agent, such as potassium dichromate or sodium dichromate.

Fluorination: Similar to the synthesis of DFB, the introduction of fluorine atoms is required to obtain DFDPS. This step can be achieved through fluorination reactions using appropriate reagents like hydrogen fluoride (HF) or elemental fluorine (F2).

It's worth noting that the processes described above are simplified summaries and may not cover all the specific details or conditions required for each step. The actual synthesis procedures for these compounds can be more intricate, involving multiple purification steps, reaction optimizations, and safety considerations.

To ensure safe and accurate synthesis, it is strongly advised to consult experienced chemists or professionals in the field of polymer synthesis or organic chemistry. They can provide guidance on specific reaction conditions, safety measures, and proper handling of chemicals."

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With all of that in mind, let's get back to the DIY electric motors that I was intending on making.

So, the idea was to take the iron/ferrite/nickel powder and also use it to make the soft magnetic composite cores of the stator of the electric motors.

However, as I already said, iron/nickel powder are expensive as f-ck, and I can't just "make" my own iron/nickel powder with a saw or something like that, the materials would simply react with other stuff in the ambient and chemically change for something not as useful for magnetic cores.

However, with the electroplating idea (that I took too long to remember and even consider doing), there could be another way of doing the electric motor.

The stators are built from laminations, metal plates are cut into shape and stacked together in order to make the stator, then the copper wire is coiled around the teeth/slots of the structure.

However, with the electroplating in mind, I could simply take aluminium foil cut into shape and put it in the electroplating with both iron, nickel and even, maybe, silicon metal.
I say maybe, because I couldn't find any electroplating tutorial on the subject and ChatGPT is saying that since the metal is a semiconductor and a reactive metal that could have unwanted reactions with the electroplating solution, so sputtering would be advised.

The problem is that sputtering, even though you can make it DIY, is still a little bit... Expensive. It is not *that* expensive, to be honest, but I'm broke. lol
Still, I think it is better to do Sputtering than electroplating, because it is way faster.

Also, I thought on something interesting for the electroplating technique.
Basically, the idea would be to put a crapton of conductive particles on the electroplating bath and keep these moving with some pump or mixer motor, the particles of graphite/graphene or other material would eventually be covered in iron/nickel/silicon and eventually making a composite that could both be used as the soft magnetic composite core and hydrogen fuel cell catalyst.

But since you would have electroplating to begin with, and thus, be able to cover the electrodes of the fuel cell or the laminations of the electric motor, I don't really know why even bother with this step... hum... Maybe it would be useful if you wanted a Oxygen Scrubber?

Also², you don't really need aluminium laminations, you could simply use paraffin mixed with graphite or other conductive material and electroplate it.
This was how NASA made some older rocket nozzles:
(both videos are relevant to understand the pros and cons of electroplating, with its challenges and everythign in between)