Engineering

570 Articles

Reconductoring: Building Tomorrow’s Grid Today

June 11, 2025 by 56 Comments

What happens when you build the largest machine in the world, but it’s still not big enough? That’s the situation the North American transmission system, the grid that connects power plants to substations and the distribution system, and which by some measures is the largest machine ever constructed, finds itself in right now. After more than a century of build-out, the towers and wires that stitch together a continent-sized grid aren’t up to the task they were designed for, and that’s a huge problem for a society with a seemingly insatiable need for more electricity.

There are plenty of reasons for this burgeoning demand, including the rapid growth of data centers to support AI and other cloud services and the move to wind and solar energy as the push to decarbonize the grid proceeds. The former introduces massive new loads to the grid with millions of hungry little GPUs, while the latter increases the supply side, as wind and solar plants are often located out of reach of existing transmission lines. Add in the anticipated expansion of the manufacturing base as industry seeks to re-home factories, and the scale of the potential problem only grows.

The bottom line to all this is that the grid needs to grow to support all this growth, and while there is often no other solution than building new transmission lines, that’s not always feasible. Even when it is, the process can take decades. What’s needed is a quick win, a way to increase the capacity of the existing infrastructure without having to build new lines from the ground up. That’s exactly what reconductoring promises, and the way it gets there presents some interesting engineering challenges and opportunities.

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Is The Atomic Outboard An Idea Whose Time Has Come?

June 10, 2025 by 45 Comments

Everyone these days wants to talk about Small Modular Reactors (SMRs) when it comes to nuclear power. The industry seems to have pinned its hopes for a ‘nuclear renaissance’ on the exciting new concept. Exciting as it may be, it is not exactly new: small reactors date back to the heyday of the atomic era. There were a few prototypes, and a lot more paper projects that are easy to sneer at today. One in particular caught our eye, in a write-up from Steve Wientz, that is described as an atomic outboard motor.

It started as an outgrowth from General Electric’s 1950s work on airborne nuclear reactors. GE’s proposal just screams “1950s” — a refractory, air-cooled reactor serving as the heat source for a large turboprop engine. Yes, complete with open-loop cooling. Those obviously didn’t fly (pun intended, as always) but to try and recoup some of their investment GE proposed a slew of applications for this small, reactor-driven gas turbine. Rather than continue to push the idea of connecting it to a turboprop and spew potentially-radioactive exhaust directly into the atmosphere, GE proposed podding up the reactor with a closed-cycle gas turbine into one small, hermetically sealed-module. Continue reading “Is The Atomic Outboard An Idea Whose Time Has Come?” →

Information Density: Microfilm And Microfiche

June 9, 2025 by 17 Comments

Today, we think nothing of sticking thousands of pages of documents on a tiny SD card, or just pushing it out to some cloud service. But for decades, this wasn’t possible. Yet companies still generated huge piles of paper. What could be done? The short answer is: microfilm.

However, the long answer is quite a bit more complicated. Microfilm is, technically, a common case of the more generic microform. A microform is a photographically reduced document on film. A bunch of pages on a reel of film is microfilm. If it is on a flat card — usually the size of an index card — that’s microfiche. On top of that, there were a few other incidental formats. Aperture cards were computer punch cards with a bit of microfilm included. Microcards were like microfiche, but printed on cardboard instead of film.

In its heyday, people used specialized cameras, some made to read fanfold computer printer paper, to create microfilm. There were also computer output devices that could create microfilm directly.

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The Potential Big Boom In Every Dust Cloud

June 2, 2025 by 49 Comments

To the average person, walking into a flour- or sawmill and seeing dust swirling around is unlikely to evoke much of a response, but those in the know are quite likely to bolt for the nearest exit at this harrowing sight. For as harmless as a fine cloud of flour, sawdust or even coffee creamer may appear, each of these have the potential for a massive conflagration and even an earth-shattering detonation.

As for the ‘why’, the answer can be found in for example the working principle behind an internal combustion engine. While a puddle of gasoline is definitely flammable, the only thing that actually burns is the evaporated gaseous form above the liquid, ergo it’s a relatively slow process; in order to make petrol combust, it needs to be mixed in the right air-fuel ratio. If this mixture is then exposed to a spark, the fuel will nearly instantly burn, causing a detonation due to the sudden release of energy.

Similarly, flour, sawdust, and many other substances in powder form will burn gradually if a certain transition interface is maintained. A bucket of sawdust burns slowly, but if you create a sawdust cloud, it might just blow up the room.

This raises the questions of how to recognize this danger and what to do about it.

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Remotely Interesting: Stream Gages

May 28, 2025 by 32 Comments

Near my childhood home was a small river. It wasn’t much more than a creek at the best of times, and in dry summers it would sometimes almost dry up completely. But snowmelt revived it each Spring, and the remains of tropical storms in late Summer and early Fall often transformed it into a raging torrent if only briefly before the flood waters receded and the river returned to its lazy ways.

Other than to those of us who used it as a playground, the river seemed of little consequence. But it did matter enough that a mile or so downstream was some sort of instrumentation, obviously meant to monitor the river. It was — and still is — visible from the road, a tall corrugated pipe standing next to the river, topped with a box bearing the logo of the US Geological Survey. On occasion, someone would visit and open the box to do mysterious things, which suggested the river was interesting beyond our fishing and adventuring needs.

Although I learned quite early that this device was a streamgage, and that it was part of a large network of monitoring instruments the USGS used to monitor the nation’s waterways, it wasn’t until quite recently — OK, this week — that I learned how streamgages work, or how extensive the network is. A lot of effort goes into installing and maintaining this far-flung network, and it’s worth looking at how these instruments work and their impact on everyday life.

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EMF Forming Was A Neat Aerospace Breakthrough

May 23, 2025 by 9 Comments

Typically, when we think about forming metal parts, we think about beating them with hammers, or squeezing them with big hydraulic presses. But what if magnets could do the squeezing? As it turns out—Grumman Aerospace discovered they can, several decades ago! Even better, they summed up this technique in a great educational video which we’ve placed below the break.

The video concerns the development of the Grumman EMF Torque Tube. The parts are essentially tubes with gear-like fittings mounted in either end, which are fixed with electromagnetic forming techniques instead of riveting or crimping. Right away, we’re told the key benefits—torque tubes built this way are “stronger, lighter, and more fatigue resistant” than those built with conventional techniques. Grumman used these torque tubes in such famous aircraft as the F-14 Tomcat, highlighting their performance and reliability.

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A Brief History Of Fuel Cells

May 22, 2025 by 13 Comments

If we asked you to think of a device that converts a chemical reaction into electricity, you’d probably say we were thinking of a battery. That’s true, but there is another device that does this that is both very similar and very different from a battery: the fuel cell.

In a very simple way, you can think of a fuel cell as a battery that consumes the chemicals it uses and allows you to replace those chemicals so that, as long as you have fuel, you can have electricity. However, the truth is a little more complicated than that. Batteries are energy storage devices. They run out when the energy stored in the chemicals runs out. In fact, many batteries can take electricity and reverse the chemical reaction, in effect recharging them. Fuel cells react chemicals to produce electricity. No fuel, no electricity.

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