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A Battery Spot Welder Made from an Old Microwave and Excessive Mahogany [video]

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Re: A Battery Spot Welder Made from an Old Microwave and Excessive Mahogany [video]

#31

What are the dangers here? What happens if that thin insulation between the copper bars breaks? Can the current jump to you if you use this bare handed?

The most dangerous thing here is energizing a MOT with its stock deadly high-voltage secondary coil. If you re-wind the secondary to be low voltage as described in the video, it's no more dangerous than any other project requiring a mains power supply.

Re: A Battery Spot Welder Made from an Old Microwave and Excessive Mahogany [video]

#32

Isn't it incredibly dangerous to disassemble microwaves?

It's less dangerous than servicing CRT televisions/monitors. If you know how to safely discharge the big capacitor and never try to energize (or dismantle) the magnetron, it's pretty benign.

Re: A Battery Spot Welder Made from an Old Microwave and Excessive Mahogany [video]

#33
post #29
post #15

Earlier quoted context omitted.

Well it's only 2 volts. So nothing will happen. Unless your hand is all sweaty maybe. Then maybe you'll feel it. I wouldn't worry.

uh... wut I believe it's the amps you need to worry about; "amps kill." I believe it takes about 1 amp to kill a person. This thing is outputting somewhere around 55 amps (if I remember right).

Current availability is not a guarantee of current delivery.

I (current) = V (voltage)/R (resistance)

Typical skin resistance can be as high as 100MΩ (mega ohms) but is often cited as 10MΩ. Even if we assume just 1MΩ (1000000 ohms) skin resistance, then at 2.3V as shown in the video the current would be 0.0000023 A or 2.3 μA (micro amperes).

Re: A Battery Spot Welder Made from an Old Microwave and Excessive Mahogany [video]

#34
post #23
post #20

These MOT based spot welders transfer far more heat to cells than capacitive discharge welders. This can result in the damage to heat sensitive components inside the cells which is the same reason that soldering isn't recommended for lithium cells. To get around those issues, I built a capacitive discharge spot welder for tabbing lithium ion cells a couple years ago: http://robruark.com/projects/welder/welder.html

What is the cause of the excess heat transfer? Is it mainly an excess pulse duration? I notice that the project in the OP was being pulsed on the order of 100s of ms, long enough to get a visible glow. Or is the excess heat caused by the fact that the OP runs at constant current for the entire duration of the pulse, where a capacitive discharge design is going to have the current falling off during the pulse? Or is i…

It's excess pulse duration coupled with insufficient current. Capacitors can dump all their energy almost instantly (on the order of 1000s of amperes), but transformers are much more current-limited due to their design. It's analogous to using a press vs a hammer.

Re: A Battery Spot Welder Made from an Old Microwave and Excessive Mahogany [video]

#35
post #21

Earlier quoted context omitted.

The magnetron can have insulators made of a toxic substance that can be dangerous as a dust. This guy is just using the transformer for it's convenient laminates and primary winding - probably could have used a similar transformer with suitable current handling capacity but dead microwave ovens are fairly common. I have 3

Some beryllium ceramics I heard...

Only dangerous if you grind/crush the very obvious pink ceramic and inhale the dust. https://en.wikipedia.org/wiki/Berylliosis

Modern magnetrons tend to use alumina-based ceramics instead.

Re: A Battery Spot Welder Made from an Old Microwave and Excessive Mahogany [video]

#36
post #20

These MOT based spot welders transfer far more heat to cells than capacitive discharge welders. This can result in the damage to heat sensitive components inside the cells which is the same reason that soldering isn't recommended for lithium cells. To get around those issues, I built a capacitive discharge spot welder for tabbing lithium ion cells a couple years ago: http://robruark.com/projects/welder/welder.html

I used to get a kick in middle school disassembling disposable cameras (unlimited supply since dad worked in a grocery store with a photo lab), charging the circuit, and discharging on coins.

Re: A Battery Spot Welder Made from an Old Microwave and Excessive Mahogany [video]

#37
post #36
post #20

These MOT based spot welders transfer far more heat to cells than capacitive discharge welders. This can result in the damage to heat sensitive components inside the cells which is the same reason that soldering isn't recommended for lithium cells. To get around those issues, I built a capacitive discharge spot welder for tabbing lithium ion cells a couple years ago: http://robruark.com/projects/welder/welder.html

I used to get a kick in middle school disassembling disposable cameras (unlimited supply since dad worked in a grocery store with a photo lab), charging the circuit, and discharging on coins.

At my middle school we discharged them on our friends…

Re: A Battery Spot Welder Made from an Old Microwave and Excessive Mahogany [video]

#38
post #29
post #15

Earlier quoted context omitted.

Well it's only 2 volts. So nothing will happen. Unless your hand is all sweaty maybe. Then maybe you'll feel it. I wouldn't worry.

uh... wut I believe it's the amps you need to worry about; "amps kill." I believe it takes about 1 amp to kill a person. This thing is outputting somewhere around 55 amps (if I remember right).

That's only half true. amp is a nano bitch without volt, and vice versa.

Re: A Battery Spot Welder Made from an Old Microwave and Excessive Mahogany [video]

#39
post #29

Earlier quoted context omitted.

uh... wut I believe it's the amps you need to worry about; "amps kill." I believe it takes about 1 amp to kill a person. This thing is outputting somewhere around 55 amps (if I remember right).

Current availability is not a guarantee of current delivery. I (current) = V (voltage)/R (resistance) Typical skin resistance can be as high as 100MΩ (mega ohms) but is often cited as 10MΩ. Even if we assume just 1MΩ (1000000 ohms) skin resistance, then at 2.3V as shown in the video the current would be 0.0000023 A or 2.3 μA (micro amperes).

TIL. Thanks for taking the time to explain!

Re: A Battery Spot Welder Made from an Old Microwave and Excessive Mahogany [video]

#40
post #21

Earlier quoted context omitted.

The magnetron can have insulators made of a toxic substance that can be dangerous as a dust. This guy is just using the transformer for it's convenient laminates and primary winding - probably could have used a similar transformer with suitable current handling capacity but dead microwave ovens are fairly common. I have 3

Some beryllium ceramics I heard...

As far as I can tell, that's a myth --- beryllia was only used in military radar magnetrons, not consumer microwave oven ones. It is extremely expensive, its other characteristics are not required, and its toxicity requires special handling measures during manufacturing, so alumina is used instead.
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