By
ironbut at 2008-09-01
Ok,.. just a little head basics. I won't go into lots of technical stuff since this is a beginners guide. Heads are (see top illistration) made of laminations of alloys in 2 main parts. If you look at the bottom cross section, there's a right and left half. To orient you, the tape would be traveling left to right or right to left across the top of the bottom picture. You can see that the haves are made up of "C" cores just like some transformers. Between these cores is a small space called the gap (of all things). The gap is the muzzle of the head. It's where the magnetic flux is allowed to flow out of the head and magnetize the tape. There's a spacer placed into the gap and the whole thing is epoxied into a single piece. One thing to keep in mind with these transducers is the extreme tolerances that they are machine and polished to (we're talking micro inches here). And just like lot's of things here on the planet earth, the material that heads are made of are a balancing act of compromises. In this case, it's between permeability and hardness (output and wear characteristics).
You might ask about the "glass" heads that Sony and Akai used in many of their latter models. I owned a couple of those and the problem with those heads is that they don't wear like a metal head which is usually pretty regular and smooth. They develop microscopic shearing of the crystals that surround the gap. After a while these develop into micro-chips (Hey,.. don't go there CV!) and can do real damage to your valuable tapes without you ever knowing it. Once they go bad, they have to be replaced.
With metal heads after they get worn, they can still be resurfaced (lapped). If you look at the first illustration there's a area on the top labeled "Depth of Gap". When a head wears, a flat spot begins to appear where the tape makes contact. An extreme case of this can be seen in the photo on the right. A head can be relapped until the "depth of gap" begins to equal zero. Since the gap spacer is just that, a spacer, when the gap begins to open up like the track on the bottom of the photo. That head is history.
When the wear isn't nearly as extreme as it is in the photo, the head can be reshaped and polished. How fast a head wears depends on several things.
The hardness of the metal the head is made of.
The speed that the machine is used (30 inch per second machines will wear out heads much faster than 7.5 ips machines)
The abrasiveness of the tape that's used.
The tape tension the machine is set at.
The cleanliness of the tape path and tapes.
Proper adjustment of the heads and guides.
Temperature and humidity (heads will rust ).
Most machines you'll come across aren't going to be as obviously worn at the picture above and to get a good idea of the wear you should use a magnifier of some sort and a good light. Look for the shinny flat spot (which all will have to some degree) and the real tell tail clue is grooving. This is something that you can feel. A head that needs relapping will have a ridge that you can feel with your fingernail (be very gentile, remember some of these heads are made of soft metals and you don't want any scratches on them). Even if you feel this ridge, it doesn't mean that the heads that worn either. Many heads have what's called "edge relief slots" cut into the surface right where these ridges would normally be found. They're there to keep the tape edge from being damaged by a ridge and also to prevent shedding oxide from being trapped along these ridges and escalating the tape and head wear. So, unless you get a good look at the head, you may just be feeling these slots. Also, it's important to see if the wear is even or not. That will tell you more about the condition and adjustment the heads and tape path were in during the majority of service. These are all great clues on how well the machine was cared for or if it was taken to a total hack for regular servicing. If you already own the machine, examining the head wear pattern will tell you if you need to take it in for adjustment. Worn heads can result in high frequency loss, excessive tape wear, inconsistent output (dropouts) and loss of overall output. As you can see from the open gap on the bottom of the head in the photo that this machine either needed to have the heads or guides adjusted. If the uneven wear (from top to bottom) was the result of the head being tilted back, the adjustment that would correct this (here it comes!) is called Zenith.
Just a few more things about heads for this post.
If you should need or choose to replace your playback head/s here's the main things you need to know when you choose one. The two spec's usually associated with them is DCR and fluxivity measured in nano Webers per meter (nWb-m). A service manual will have these figures. The fluxivity is a reference number when you wish to choose an alignment tape too. 185 to over 500 nWb-m heads can be found. Aside from those two figures, many times space available will be another determining factor for which heads can be used with a particular machine. Remember that with playback heads they almost always have a shield around them so the fit can be tight.
If you're interested in more info regarding relapping and head wear, John French is the man and his web site is full of info.
http://jrfmagnetics.com/Here's JFR's procedure when relapping heads:
In the JRF alignment procedure each head (erase, record and playback) is
aligned for track placement (referenced to the tape guides and set within
.0005), zenith (90 degree tilt), wrap (gap centered on tape contact scrub
pattern), and azimuth (90 degrees). Head assemblies that do not have tape
guides attached to the head plate are mounted on our lab fixtures that
simulate the recorder tape path (with guides for height reference).
Upon re-installation of our optically aligned assembly we recommend the
use of a test tape to optimize the azimuth for phase. This is required
because of the tolerance differences between tape width (typically .246)
and guide width clearance (.252). As you can see, there is about .006
clearance which can allow the tape to enter the assembly incoming guide
low (or high) and exit the outgoing guide high (or low). This potential
tape path error along with the quality of the tape slitting
and/or other components in the tape path (such as the pinch roller) will
have an effect in the azimuth that cannot be anticipated in the lab. We
are generally dead on about 70% of the time however, I always recommend
the use of a test tape.