Microsquare magnet wire

[brenthusum]

Anybody play around with microsquare magnet wire from MWS Wire Industries? http://www.mwswire.com/microsq.htm

[DadHav]

Hello Brent, I already have samples of this wire coming. For the most part, just because I'm curious. The aluminum square in sizes of #22 or #24 would cost about $1.05 US per foot, with the copper at about $.85. But Man: I think an alluminum wound stator should work really good. Square would give a good wind, while being more conductive, not to mention lighter. Would it be worth the cost if you were really making something special? I'm thinking aluminum wire and magnesium bearing holder, mount and bell.

C YA

John H.

[ScubaSteve]

If I'm reading the info below, copper has lower resistance and better thermal conductivity. The only advantage I see to the aluminum is maybe the weight savings, which I think is pretty minimal if even noticeable.

You're talkin' 9 gm/cc for copper vs. around 3 for aluminum... If you're even putting a cubic cm of wire on a stator, maybe a 6 gram savings? On top of that, I also think to induce the same field using alum as copper, you're gonna need more aluminum, which means more wire, which means more weight...

COPPER

GENERAL PROPERTIES
Symbol: Cu
Atomic Number: 29
Atomic Weight: 63.546
Density: 8.96 gm/cc
Melting Point: 1083.4 oC
Boiling Point: 2567 oC
Thermal Conductivity: 4.01 W/cm/oK @ 298.2 oK
Electrical Resistivity: 1.678 microhm-cm @ 20 oC
Electronegativity: 1.9 Paulings
Specific Heat: 0.092 Cal/g/oK @ 25 oC
Heat of Vaporization: 72.8 K-cal/gm atom at 2567 oC
Heat of Fusion: 3.11 Cal/gm mole

MATERIAL OVERVIEW
Characteristics: Distinctive reddish color; ductile; excellent conductor of electricity. Complexing agent, coordination numbers 2 and 4. Dissolves readily in nitric and hot concentrated H2SO4, in HCl and dilute H2SO4 slowly but only when exposed to the atmosphere. More resistant to atmospheric corrosion than iron, forming a green layer of hydrated basic carbonate. Readily attacked by alkalies. A necessary trace element in human diet; a factor in plant metabolism. Essentially nontoxic in elemental form. Powder is combustible.

ALUMINUM

GENERAL PROPERTIES
Symbol: Al
Atomic Number: 13
Atomic Weight: 26.98154
Density: 2.6989 gm/cc
Melting Point: 660.37 oC
Boiling Point: 2467 oC
Thermal Conductivity: 2.37 W/cm/oK @ 298.2 oK
Electrical Resistivity: 2.6548 microhm-cm @ 20 oC
Electronegativity: 1.5 Paulings
Specific Heat: 0.215 Cal/g/oK @ 25 oC
Heat of Vaporization: 67.9 K-cal/gm atom at 2467 oC
Heat of Fusion: 2.55 Cal/gm mole

MATERIAL OVERVIEW
Characteristics: Silvery white, crystalline solid. Tensile strength (annealed) 6800 psi, coldrolled 16,000 psi. Forms protective coating of Al2O3 about 50 thick, which makes it highly resistant to ordinary corrosion. Attacked by concentrated and dilute solutions of HCl, hot conc. H2SO4 and perchloric acid, also violently by strong alkalies. Rapidly oxidized by water at 180 oC. Not attacked by dilute or cold concentrated H2SO4 and concentrated nitric acid. Electrical conductivity about 2/3 that of copper. Aluminum qualifies as both a light metal and a heavy metal, according to their respective definitions.

[DadHav]

Great information Steve. Thank's. I appreciate you going through the trouble. After checking back on the site, I found your data to be correct. The resistance of the aluminum wire is 26.52 ohms per 1000 ft. The weight thouh, is about 2/3 that of the copper. I will be getting a copper sample as well. It might be interesting to see how it winds. I'm getting away from single strand winding though and have been winding with three strand. Man, I like that a lot. Check the pictures if they load. But don't make fun of my test stand. I hook the digital fish scale to the back of it to test torque. Sorry, I got a promp saying that my attachments can't upload to /uploads/ The pics are JPEG / 640/480. Any advise on this?

Steve, I'm probably going to be adding this post several times again because I keep trying to submit pictures. If so, would you be kind enough to delete the mess?

C YA

[ScubaSteve]

Hey John,

Just edit the message rather than reposting it. I just fixed the upload snafu... something I forgot to change after switching hosts. :oops:

But I just tested it, and the upload feature is 100% functional again! :D

[Q]

Using a tripple wind on square wire might be a very good idea, but it must be very hard to avoid the wire from twisting. If it does twist the square wire uses more space than a round one and your gain is all gone. Let us know how it goes.

[DadHav]

Thank's Steve the picture upload worked. I put them in the wrong place, so I'll add them again here.
Hi Bert, I think I didn't explain well enough about the wire. I have samples of #22 and #24 square coming. I think this wire would be good enough for a single wind. What do you think? I have been winding using 3 strands of #30 and I really like windin this way. Maybe I'm backwards, but I don't use a vise or anything to hold the stator when winding. I guide the three strands through my thumb and forfinger while turning the stator around and around to accept the wire. This is easy to keep the three strand winding seperated and with the same tension. The wind, though, is random after about the first trip up the leg. I don't know if it's the acceptable way but the motors are running good. The pictures below show my 22.7 double stator motor with 12 turns. The motor is pulling 24 oz. on my digital fish scale. The prop is 9-5 Graupner Slim or APC 9-4/5. drawing about 11 amps with a three cell 2100 lithium. I'm pretty satisfied with the performance. I'm going to move up to some 12 leg stators to see what I can come up with.

Thanks
John

[Tubes]

Hello DadHav
Where did you get that endbell and mount, it looks real nice!
Thanks

Reuben

[DadHav]

Hi Reuben, Thanks for the compliment. I'm proud to say that I made them myself. This is almost as much fun as building and flying planes.
I buy everything I can from GB and then go the extra mile with the custom parts.

RGDS.

John H.