Aluminum Casting with UPS Transformer - No Induction Heater

Melting of Aluminum can easily be achieved by shorting a graphite crucible with UPS Transformers. A big enough setup can actually replace induction heaters for this job.
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#aluminum #casting #transformer #inductionheater #aluminumcasting #mrelectron

[@MrElectron]

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[@jozefnovak7750]

Thank you.

[@joelfenner]

Over 20 years ago, I was doing patent research, and I ran across a ca.1910 US patent (yes, THAT old) for an alloy and its method of preparation that involved an electrically heated graphite crucible. The patent was old enough that passing current directly through the crucible wall was actually the heating method (predated common use of induction heating). The patent contained a diagram of the crucible, which was supposed to be novel, and the alloy composition accounted for a certain amount of the crucible wall (intentionally) dissolving into the final alloy on each new melt. I'd never seen a similar process used until this video. As it was not a part of common industry practice today, I assumed there was some reason it fell out of favor.

[@colinkraus7139]

Wires everywhere!!!! My kind of channel!!!! Instant sub.

[@MrElectron]

Welcome aboard ! 😀

[@tyler5120]

@@MrElectron All aboard the Darwin Express! End destination, your very own Darwin Award. Thanks for playing.

[@bernardb8045]

Outstanding project! Genius in its simplicity, thank you sir

[@MrElectron]

You are welcome. Glad you like it! 😀

[@V1P3RSlab]

those sharp points in the contacts, where also a big risk for arcing :D .... you get rid of them at the end of the video, but was important to highlight the problem 🙂

[@MrElectron]

That was not the reason because of which i removed it. The bigger size of the contacts increased the current flow, so to reduce that current, i shortened them.

[@KallePihlajasaari]

There was only 7V on the transformer output. No chance of arcing between the terminals. Having the contacts just flat with a small gap in between would probably have been the best for any size crucible.

[@PatrickBaptist]

First time viewer, dunno how I ain't seen this channel before, thanks I enjoyed, and going to make my own from a large welder transformer.

[@jeffreyrood8755]

Nicely done.

[@jozefnovak7750]

Super! Thank you very much!

[@MrElectron]

You are welcome 😊

[@TheAxeljones2012]

congratulations!!

[@Александр-ш4к5г]

Замечательно! Так держать! Лайк Вам! На удачу!

[@didehban1]

Good tanks youre very perfect explain problem and youre aid good blesing and good luck

[@MrElectron]

Thanks 😊

[@josmaraugustofonsecabarbos1713]

I liked your implementation! Welding and melting metal with transformer is a great idea!

[@bob_mosavo]

Thanks 👍

[@rockmonkfuture7926]

Surface tension of molten Aluminum drop ruined the casting part..😋😂

[@ValeryDjondo]

Any idea to reduct surface tension on aluminum ?

[@Cassiusisback]

@@ValeryDjondo remove slag before casting :) and get it hot enough.

[@oldschoolmoto]

great vids very informative i have a older honda 4500 watt portable gas generator it is 220 0nly no 115 or 120 receptacals is the any way to run 115 or 120 of it i dont want to fry any of my 115 tools

[@MrElectron]

Thanks !! Sure. Get a step down transformer that can convert your 220v to 110v AC or make one yourself. It will be fun 👉 kzbin.info/www/bejne/nX-llXuapZ6pa6csi=dQiQUAYQllGuXtyP

[@shamirkhan6210]

You can slow down the speed of the engine to get 120 voltage or just get a 220 to 110 step down transformer to run your 110 equipment by just plugging in the 220 input side of the transformer into the generator output socket and then take the 110 voltage from the transformer output side which is 110 voltage...that is easier that slowing down the gasoline engine to obtain 110 voltage output which i have done that on my 48 feet ice fishing boat and used mu generator fir a number of years without any problems my generator was a poratable 220 voltage gasoline generator 2000 watts .

[@diymaster101]

Amazing work very good I really this project ❤👏🏾 amazing.

[@coreyellisart6877]

You should try a saturated inductor like what they use for a welder. An old large Transformer you run your line through one side of the Transformer the higher current side and then the lower current side you run around 24 V DC on a small little potentiometer. The more DC that saturates the Transformer the less electrons can flow through which in turn creates resistance

[@jahmahrahdesafilli6268]

Hi, A little trick when safely joining high voltage wires like 240 volts is to use wago connectors. Best Wishes Jahmahrah

[@manikanta-u6r]

can we get 15A continuous current from 1 UPS transformer ???

[@SpencerHHO]

Get a transformer out of an old transformer arc welder. I haven't seen one do less than 100 amps and even relatively cheap units often do 200amps. Transformer welders usually have multiple Taps in the windings or a variable distance between the primary and secondary windings allowing for much more control. You should also try using an Arc to melt the metal. Have the crucible + and a graphite rod - and short the rod directly to the metal in the crucible so more of the heat goes into the actual metal and not everything else.

[@mikegLXIVMM]

I wanted to make a small carbon arc furnace. Maybe this is the transformer I need.

[@anonymously241]

Good job Bhai 👍💯

[@natanaelescalante6155]

Deberías doblar tus videos al español. Tienes muy buen contenido pero dejamos a un lado el video cuando se nos va el tiempo en leer subtitulos. Saludos y excelente contenido.

[@AlbinoGomesLeal-q3k]

Parabéns, muito inteligente !

[@joecrisp9060]

Seems like I remember reading that commercial aluminum smelting is done using carbon electrodes dipped into the melt instead of heating the crucible itself. Could use your bushes to touch the aluminum and heat it directly.

[@anthonywilliams7052]

How much current is this drawing from the outlet / primary? Is this 120v or 220v, what are the transformer ratings? Maybe tell people to not breath the fumes too, some of the plating like zinc and cadmium can be DEADLY.

[@davicorreiadasilva8732]

😮 posso fazer com transformador de micro ondas?

[@MrElectron]

Sure

[@BensWorkshop]

You could just make a carbon furnace. Contact on the crucible, and the other to a carbon rod. Place scrap in the crucible and hit with the carbon rod.

[@ابوعبداللهالفقيه-د9ح]

How to know is the In put And know the wire out put

[@Delphis1982]

Safety first, so I put on my security gloves... with open fingers. That's my kind of humor.

[@solvated_photon]

3:28 “safety should always be first” *cuts the fingers off of the gloves

[@neroncrasso]

Najveći problem su te željezne pločice koje imaju prevelik otpor i još su korodirane. Aluminij se inače bez problema topi u džezvi za kavu.

[@EcoinnovaAndina]

Saludos, buen experimento, tocaria comparar eficiencia contra inducción

[@sfdxshow]

xd--- plomo no aluminio

[@MrElectron]

It's aluminum and not lead. Lead is much heavier and more soft.

[@RixtronixLAB]

Creative video, thanks :)

[@logictv6667]

Nice content

[@logictv6667]

1:00

[@jeffreyyoung4104]

I wonder if you use two carbon rods dipped in aluminum dust which is in a ceramic crucible, if the aluminum will melt, then add borax, and refine more aluminum from the borax?

[@qwertyytre9460]

Стальной тигель "N" , а УГОЛЬНЫЙ электрод "P" в центре тигеля - ВСЁ 😌

[@mipad553]

How much watts of power consume 10mm iron rod to red hot and 10mm×2cm iron rod to melt?

[@mathieupierremarceaupaulin5298]

🙃Belle histoire du creuset graphite à l'usage de résistance🙃 La consommation électrique semble energivore connecté en direct sur les transformateurs!

[@mathieupierremarceaupaulin5298]

Ajuster la fréquence à augmenter la résistance interne du graphite... Produire l'onde sinusoïdale a partir d'un aimant puissant en rotation sur un petit moteur type mini ventilateur 0.05A.... ¿"!"? L'induction 50Htz du réseau électrique à l'utilité de réchauffer l'atmosphère par effet joule et effet de peau mais peu le métal d'oú l'usage des 50Htz sur le réseau‼️‼️‼️

[@hiRafia]

سيكون استهلاك الطاقة خرافي

[@2pist]

Hmmm. Pretty cool idea.

[@tntomega]

the easy way is to connect direct to electric company

[@Cassiusisback]

i would have loved to see voltage measured at transformer side and crucible side, so i can estimate the power losses.

[@ФаррухМахмудов-и6ь]

Hello of Russia✋👋

[@mohdhaseeb8009]

Are You Looking For Video Editor?

[@MrElectron]

Not right now but may be after 2 or 3 months.

[@mohdhaseeb8009]

Okay Sir @@MrElectron

[@IanBrodie-bg1lu]

Guaranteed high resistance where the copper cable meets the iron tie wire/

[@ابوعبداللهالفقيه-د9ح]

كيف يمكنني معرفه مكان الدخول والخروج في المحول الكهربائي

[@Chromevulcan]

How are you still alive?

[@dnzssrl]

fr

[@dazai_osamu777]

Where you get many ups transformers?

[@MrElectron]

I have 15 more 😀😀😀. Planning something big a future project.

[@dazai_osamu777]

@@MrElectron I have only one from old 24v ups 😅 I'm trying my idea project... Ok good luck bro I'm waiting 😁

[@dazai_osamu777]

@@MrElectron MrElectron ,12v and 24 ups transformers are different or same? Please tell me

[@dazai_osamu777]

@@DonnieLuve yeah thanks for the reply😊... According to my opinion, maybe the secondary winding of the ups transformer is different between 12v and 24v ups transformer

[@dazai_osamu777]

@@DonnieLuve wow that sounds cool yeah... But if the transformer ferrite core or steel core , it's small and we give the same turns of copper, maybe the output will changes.. I've not study much about transformers in high school, I'll try to study more..

[@neoprints1325]

Can we use welding transformer?

[@MrElectron]

What is the output voltage of a welding transformer

[@zsoltsebo3158]

24V and up to 140-160A

[@iraK-i9k]

@@MrElectron 200A

[@face_to_quran]

Make another part

[@MohammadNizamuddinKamawat]

Instead of so much transformer can we use microwave transformer

[@mrelectron_alternator]

Sure

[@SpencerHHO]

You'd have to modify the secondary windings for a few turns of a thick gauge wire. A standard MOT would only output a couple of amps at 2000V which wouldn't melt much but would kill you instantly if you touched it.

[@حمزةبنصايل]

السلام عليكم ورحمة الله وبركاته هل. يذوب الحديد

[@MrElectron]

May it be upon you too brother 😊

[@THEATREGOD3]

what kind of computers are you getting those CPU transformers out of

[@hexagonal7708]

you can also use microwave transformers which are a bit bigger

[@pattwidale4045]

It would be important to not let the smoke out of the stack of transformers.

[@klausbrinck2137]

I liked it a lot...!!! Can I use microwave-oven-transformators for the job (without re-winding them), or are their primary/secondary-windings not matching the requirements ??? Thanks

[@MrElectron]

Thanks 😊 ! No you will have to rewind the microwave transformer and then only will it work

[@klausbrinck2137]

@@MrElectron Thanks...!!!

[@Drjtherrien]

Please take care! Floor tiles do not handle the stress from uneven heat distribution. I have had plenty shatter on me due to concentrated heat. Because they are serving as the base for the crucible it could be an serious accident waiting to happen if the tile shatters, tipping the crucible and then causing the molten metal to spill.

[@MrElectron]

Thanks for the pointer !

[@gnanaprakashgnanaprakash3392]

Hai bro how to make aplasma engine

[@MrElectron]

Plasma channel has already made some good projects on that.

[@ahmedelsayed6074]

انه فهمت منك الشرح اكثر من العرب وانه لا اعرف الانجليزيه

[@robertcroft2591]

Mr Safety in his lab. No tape to cover connections? Muchba melt some rubber.!

[@MegaGamerGuy1701]

@9:30, looks like lead and not aluminum.

[@MrElectron]

Its aluminum. Lead is heavy and soft

[@memyselfandi6422]

You didn't cast anything you just ended up with a big blob of aluminium.

[@ernestwilliams3112]

Yep

[@horsthacker9990]

And it looks more like zinc or something. Aluminium is more like water when fluid and also didnt melt, if the crucible is realy red. May be i am wrong, but didnt look to me, like it's aluminum. May be an alloy that looks somehow other than what i know.. i dont know. Away from that: Try not to use a small contact gap for heating the crucible. I would think a longer gap should give a bigger resistant to more fit the voltage and heat more area, so the crucible wont be cooled so much because of the area, which isnt heated by current. I would try to connect the (first round) crucible one contact at the bottom and one at the top in a ring shape, so to make a big surface contact and also heating the hole crucible by current. I would be very curious, if that would work better... Rewireing like you said would be also an idea.. but that work :) .. I had this idea in mind for a very long time and i am so happy, you done it. just to see, if it will work and under which conditions. Go on, good work !

[@Dumitrescuvasile]

Ai timp sa te joci , mai mult costă acele transformatoare decât un singur montaj ZFS inducție , mai bine luai un MOT

[@bl00dh4nd5]

Bro be careful casting with wet sand. Molten metal can jump really high when put in contact with cold or wet sand.

[@MrElectron]

Thanks

[@vanhetgoor]

The aluminium is not hot enough, you can't poor it properly.

[@flyingdutchmanindustries5877]

CORRECTION: Melting aluminum with MANY transformers.

[@gerarddugas6224]

At a metal melting pot increase voltage to 480 volts ac between carbon electrodes separated and hung above pot. Fill pot with metal you wish to melt. wear welding shield and gloves. Very slowly lower electrodes toward metal in pot. Voltage on between electrodes while lowering. When arc is born, slowly back out electrodes a little. Fan suck hose above melt to outside. This is effective and proven technology. The only heat is arc. 50 amps max. Higher voltage stops wire heat up effect you are finding problematic. I saw this in operation for real. 😮😮😮 Three phase 480volts three electrodes. A Large truck alternator with diodes taken out. Feed ABC phases to ABC ELECTRODES. ONE PHASE ONE ELECTRODE. DRIVE ALTERNATOR WITH SMALL DIESEL RUNNING ON WASTE OIL FROM GASOLINE ENGINE OIL CHANGE. GOOD LUCK SON AND HAVE FUN😂

[@MrElectron]

I'll try that. Although it seems a little dangerous because of the high voltage.Thick rubber gloves are must in that case.Thanks 😊

[@adriandumitrascu4292]

@@MrElectron its work at lower voltages, direct ac from 3 microwave oven, no connection current 60V, i was able to arc 2 carbon electrode in order to melt aluminum oxide ~2200degree Celsius, anyway probably too much current for r20 battery carbon rod coz it got destroyed in minutes, probably because exceed 3000 degree

[@AmanGupta-u2r7s]

Don't heat and burn plastic like that, some fumes are being studied for causing cancer

[@MrElectron]

@@AmanGupta-u2r7s Ohh, thanks for this knowledge 👍

[@Plotnikkk]

А что если к вашей подставочке нормальный сварочный трансформатор подключить

[@THEATREGOD3]

I am very tech savvy I have all the stuff how to build this too but no way in hell am I going to do it

[@ImamFaerozi]

Oke

[@YakobYakob-hp2js]

العلم

[@sunilgokhale612]

Do not see much advantage over induction melting 🤔

[@Олег-и7т1и]

Мне одному показалось, что этот хм... электрон ЦАМ плавил?

[@norbertbenyak7125]

100 Ampers from this transformer??? Are you joking? This is a scrap metal not a normal 100A transformer

[@adriandumitrascu4292]

its 2v 100A so 200w in total, not a big deal

[@norbertbenyak7125]

This transformer made for normal usage in computer, not for permanent shortcut to give 100 Amps. He used 6 pcs transformers but they’ll overheat and smoke shortly…👌

[@jeanpierre3193]

Ce n'est pas de l'aluminium ! C'est du plomb dans le creuset, l'aluminium ne fond pas de cette façon !

[@levieux1137]

Your secondary voltage is much too high, most of the power and heat leaves through the wires and transformers. You should connect your primaries in series (2-3 each) and the secondaries in parallel. The voltage will be lower and the current essentially the same, leading to less energy wasted there.

[@MrElectron]

I thought that too but there was another way to achieve that by adding a 2kw dimmer circuit to the primary so i did that.

[@willytarreau6017]

@@MrElectron sure but it still wastes energy in the dimmer or, if it's a switching dimmer, alternantes between high current with losses and zero, then delivers less total power. With the transformers in series by 2 or 3, you'd reduce the peak voltage to what you currently observe without heating the core and primary as much. This would also allow you to add even more transformers ;-) BTW, kudos for machining the graphite to make a current conducting crucible, I love the idea!

[@MrElectron]

Actually, what's more important is to limit the overall ouput current to 20A per transformer for which the dimmer is still necessary. I understand that by connecting the primaries in series, i can bring the output voltage down to half and even lesser output amps, but to maintain them at precise 20A , dimmer is still a necessity at the cost of some minor losses.

[@willytarreau6017]

@@MrElectron yeah, makes sense. It's still possible to combine the two, though ;-)

[@MrElectron]

Yes, it's definitely possible 😊

[@teslagamingofficial543]

Those were lead pieces, not aluminium.

[@MrElectron]

It's aluminum and not lead. Lead is much heavier and more soft.

[@iraK-i9k]

[@RoboArc]

Induction heaters are safer, this is dangerous as all fk 😂 it does work tho.

[@G.e.or.g.e]

👍💪👍

[@wolffy3883]

You burning the more expensive ups transformer so your idea is quite not good

[@TheDixtroy]

Al molding for ants.

[@diesel4338]

Take 1 microwave transformers instead

[@christophercaldwell9673]

Microwave transformer 20amps

[@estebanmurillo4431]

👍

[@YarovoLivas]

Paneer is going to kill himself

[@THEATREGOD3]

I DON'T RECOMMEND ANYONE DOING THIS

[@dorthyfletcher9750]

You lie that was lead not aluminum

[@MrElectron]

It's aluminum and not lead. Lead is much heavier and more soft.

[@Walker7745]

Столько трансформаторов... и столь мизерный результат. Знаете, где ваша ошибка? Ваши трансформаторы дают слишком высокое напряжение и вся их мощность растрачивается на нагрев обмоток. Вы получили бы лучший результат, если бы взяли всего один трансформатор (ну, возможно два), и перемотали бы вторичную обмотку. Оставили бы три-четыре витка, но гораздо более толстым проводом. Можно было использовать тот же который был, но сложить штук по пять проводов. Вот тогда вся мощность пошла бы в тигель. И он был бы ярко красным. А еще практический совет. У кого есть столько трансформаторов от ИБП? Может быть их надо купить? Сварочный инвертор обойдется дешевле. А результат точно такой же.

[@MrElectron]

It's all stated at the end of the video. Seems like you skipped it 07:28 & 08:10

[@norbertk.1473]

Nein! 😕👎

[@michaelarcher4643]

10 minutes of wasted time.

[@shamirkhan6210]

What kind of 200 amps you may think you can get out of a UP S transformer ? Is it Chinese amps ? Or UFO amps ? This not cane juice we are talking about bro ....I personally think you mean ( milli amps ) because no way you can get 200 amps from the winding of that kind of transformer...asked any arc welder they tell you that you are talking about Indian curry and roti amps.