All language subtitles for S02E13 - Ball Bearings; Electrical Wires; Lost Wax Process Casting; Automated Machines (576p AMZN WEB-DL x265 Garshasp)_track4_[eng]
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Narrator:
Today on "How it's made"...
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Ball bearings...
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Electrical wires...
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Lost wax casting...
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And automated machines.
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With all the high-tech hoopla
These days,
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The lowly ball bearing
Gets forgotten.
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But many machine parts
Need ball bearings to rotate.
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They're in household appliances,
Industrial machines,
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And car engine parts
Such as alternators and fans.
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This is what's called
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A deep groove radial
Ball bearing.
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It has steel balls that move
Inside tracks called raceways.
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The raceways are carved into
A set of heavy-duty steel rings.
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The balls are made
Of the same type of steel.
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They first prepare
To shape the rings
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To the right thickness.
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They insert the inner ring
Into the outer ring.
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The set then passes
Through a grinder
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That alters the width
To the correct thickness.
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A gauge checks the width
Of each ring as it exits.
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Now they separate
The inner and outer rings
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In order to grind
Their outer circumference
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On separate machines.
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The outer ring
Enters the grinder,
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Which shapes its outer surface
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To a precise roundness
And diameter.
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A water-based liquid
Keeps the ring from overheating,
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Which would cause warping.
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The ring exits the grinder
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Through a gauge
That checks the diameter.
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Next, the outer ring's raceway
Goes for grinding.
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Abrasive stone wheels
With an oil coolant
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Shape the surface to precisely
The correct roundness and size.
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The inner ring and raceway
Go through a similar machine.
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Now the rings go for polishing.
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An abrasive stone
Lubricated with oil
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Polishes the steel surface
Until you can see a reflection.
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Here's the before and after.
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Next stop -- washing.
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They coat the rings
With thick oil
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And a fine stone grit.
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They clean the raceways
With kerosene.
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Elsewhere in the plant,
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They classify the steel balls
According to size.
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These balls started out
As steel wire.
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A machine cut them into pieces
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And a die punched them
Into rough balls.
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Those rough balls
Go into a grinder,
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Which removes the bumps.
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Then other machines
Round them out
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And give them a mirror finish.
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This entire process
Takes a few days.
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The balls go through a furnace
To harden.
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Then they get a bath
In cleaning solvent.
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After several quality checks,
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The finished balls
Go into hoppers.
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The hoppers load onto
The automatic assembly machine.
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The ball feeder sends the balls
Through tubes
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To a ball pusher that feeds
The correct quantity of balls
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Into the raceways
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Of the now-reassembled
Inner and outer rings.
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A ball divider positions
The balls evenly
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Around the raceways.
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Next comes the ball cage,
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A metal cage that retains
The balls in position
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Around the raceways.
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The first machine
Installs half of the cage,
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The half with rivet holes.
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The next machine
Carefully positions
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The other half of the cage,
The half with rivets.
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The machine test-spins
The bearing,
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Then rivets the two halves
Of the ball cage together.
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The bearing
Is now fully assembled.
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Now it goes into a solvent bath,
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Then to a series of automated
Quality-control tests.
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This noise-vibration tester
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Makes sure the ball bearing
Operates quietly.
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Some types of bearings
Are lubricated with grease.
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A machine squirts grease evenly
Into the bearings' raceways,
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Then inserts a rubber seal
To contain the grease.
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A final quality-control test --
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An automated scale
Tosses out any bum bearings
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That aren't the required weight.
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The good ones move on
To the laser,
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Which marks them
With information
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Such as the part number
And the trademark.
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Narrator: what is
Genetically modified food?
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Scientists manipulate
The genes in crop seeds
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To increase yield
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Or to make the crop
More resistant
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To disease or insects.
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There's a worldwide debate
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Over whether this manipulation
Of nature poses a risk
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To our health
Or to the environment.
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We're so used to them
That we barely notice
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That electrical wires
Are all around us.
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They're in aerial
And underground cables
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Running along our streets
And to our homes.
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They're behind our walls
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And inside
Our electrical appliances.
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To make color-coded
Electrical wires,
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They use what's called rod,
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Made of either solid copper
Or solid aluminum.
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They feed the rod into a machine
That draws it out
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Through a series of lubricated
Pulleys and dies --
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Stretching, lengthening,
And thinning it out...
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...And eventually winding it
Onto a large bobbin.
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What was once a rod
4/10 of an inch in diameter
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Is now just 8/100 of an inch,
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The width of about
A dozen human hairs.
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They load the bobbin
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Onto what's called
A stranding machine.
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They cold-weld the end
Of one bobbin to another,
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Guaranteeing
An uninterrupted flow
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Once they start up the machine.
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At high speed,
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The stranding machine
Twists seven wires together,
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Forming an electrical conductor,
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Also called a bear conductor.
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This is a low-voltage
Conductor --
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00:08:00,275 --> 00:08:02,724
Under 1,000 volts --
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The kind you find in the cables
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00:08:04,551 --> 00:08:07,551
That run electricity
To your home.
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Bear conductors
Need to be insulated
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So the people handling them
Won't get an electric shock.
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A plastic extrusion machine
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Coats the conductor
With polyethylene or pvc.
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This insulates the conductor.
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This is what the polyethylene
Looks like in its raw form.
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As the conductor exits
The machine
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With its new insulation,
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A precision laser
Gauges the diameter
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To make sure the insulation
Is uniform
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And the right dimension.
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The extrusion process
Has heated up the conductor,
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So it has to be cooled down
With water.
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Sometimes two or more conductors
Are twisted together.
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When that's the case,
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A printing machine applies
A white stripe
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To identify which is which.
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The client who's ordered
The conductors
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Specifies the colors
Of insulation.
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It chooses them based on
How it wants to color-code
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Its electrical wiring.
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Several conductors
Are often grouped together
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To form a cable.
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The plant performs
A voltage test,
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Immersing the cables in water
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To make sure
They don't short-circuit.
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These medium-voltage cables
Can carry
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From 1,000 to 46,000 volts
Of electricity.
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They're the type used
For underground power lines.
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They're insulated the same way
Low-voltage cables are.
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The plant prints the date
Of manufacture, the voltage,
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And any other information
The client has requested.
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The cable goes onto
A reel to be tested
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Before it's shipped out
To its destination.
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In the middle of the cable,
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Surrounded by
Copper grounding wires
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And a host of other components
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Is the heart
Of the electrical cable --
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The bear conductor.
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Narrator: many machine parts
Are simply stamped or machined
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Out of solid metal,
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But parts with complex shapes
Or thin walls
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Can't be made that way.
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They have to be cast
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Using a technique called
"Lost wax process casting."
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It takes anywhere from a week
To a month
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To manufacture
A cast-metal part,
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Depending on its complexity.
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The first step is to inject wax
Into an aluminum die,
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Which is essentially a mold
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Whose cavity is in the shape
Of the part.
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This creates a wax model
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Slightly larger than
The finished part will be.
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They'll use this wax model
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To make a mold
Out of a ceramic material.
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The mold has to be larger
Than the finished part
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Because metal shrinks
As it cools.
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Once the wax model is ready,
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They stamp on a code
To tell the foundry workers
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What type of metal to use
When they cast the part.
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Next, using a hot iron,
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They attach wax components
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To create what's called
A metal delivery system --
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Channels that will funnel
The molten metal
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Into the mold's cavity.
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Next, they dip this wax assembly
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Into a ceramic solution
Called "Slurry."
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They do this by hand
To prevent imperfections
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That would cause defects
In the casting.
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To strengthen the slurry,
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They coat it
In a fine zirconium sand,
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Then let it dry.
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A robot then keeps repeating
The process with coarser sand
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Until the ceramic shell
Surrounding the wax assembly
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Is about 3/10 of an inch thick.
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This takes five days.
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Now the ceramic-covered
Wax assembly
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Is ready for what they call
The dewax.
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Workers place it in a hot-steam
Chamber called an autoclave
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For 5 to 10 minutes.
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00:13:01,827 --> 00:13:04,482
This melts the wax
Right out of the shell,
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Creating a ceramic mold
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00:13:05,965 --> 00:13:10,206
Whose cavity is in the shape
Of the part.
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00:13:10,206 --> 00:13:12,172
Once the mold has dried out,
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Workers can begin
To cast the part.
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First they put the cold mold
Into an oven
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00:13:18,103 --> 00:13:21,241
And heat it up
For two to three hours.
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00:13:21,241 --> 00:13:24,206
This prevents the mold
From cracking from shock
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00:13:24,206 --> 00:13:26,965
When it comes into contact
With molten metal
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00:13:26,965 --> 00:13:30,344
That's close to 2,200 degrees
Fahrenheit.
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00:13:31,689 --> 00:13:34,758
They pour the metal
Into the mold's cavity,
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00:13:34,758 --> 00:13:37,793
Then let it cool
And harden at room temperature.
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00:13:37,793 --> 00:13:42,862
It takes two hours for aluminum,
Four to five hours for steel.
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00:13:44,827 --> 00:13:47,551
Once the metal has cooled
And solidified,
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They break off the ceramic mold
Using a vibrating hammer.
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00:13:51,655 --> 00:13:53,931
This takes about five minutes.
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00:13:58,758 --> 00:14:02,000
They saw off
The metal delivery system...
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00:14:16,827 --> 00:14:19,896
...Then grind
The surface smooth.
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00:14:32,793 --> 00:14:34,965
The final step is to make sure
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The part came to
The exact dimensions
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Specified
In the technical drawing.
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00:14:40,413 --> 00:14:42,448
This is called "Sizing."
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00:14:42,448 --> 00:14:45,862
Steel parts have to be heated up
In an oven for sizing.
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00:14:45,862 --> 00:14:48,862
Aluminum parts are sized cold.
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00:14:51,689 --> 00:14:54,827
Technicians use a series
Of tools and presses
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To measure the part.
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00:14:56,379 --> 00:14:58,379
If it doesn't meet
Specifications,
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00:14:58,379 --> 00:15:01,896
It's either reworked
Or simply discarded.
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00:15:04,241 --> 00:15:08,034
They use sophisticated equipment
Such as this optical comparator
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00:15:08,034 --> 00:15:10,551
To check the angles and radiuses
235
00:15:10,551 --> 00:15:15,000
And this coordinate measuring
Machine to verify dimensions.
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00:15:23,172 --> 00:15:26,655
Lost wax process casting
Is used to make metal parts
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00:15:26,655 --> 00:15:29,034
For all types of machines
And equipment,
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00:15:29,034 --> 00:15:32,724
Everything from military weapons
To snowmobiles.
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00:15:41,931 --> 00:15:44,379
Narrator:
Since the industrial revolution,
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00:15:44,379 --> 00:15:48,068
Manufacturing has become
Increasingly automated.
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00:15:48,068 --> 00:15:51,103
It's about time
"How it's made" paid tribute
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00:15:51,103 --> 00:15:53,758
To that marvelous feat
Of engineering,
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00:15:53,758 --> 00:15:55,724
The automated machine.
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00:16:03,310 --> 00:16:05,655
Until the 1780s,
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00:16:05,655 --> 00:16:09,724
Goods were made one by one
In a home or workshop.
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00:16:09,724 --> 00:16:12,344
Then came
The industrial revolution,
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00:16:12,344 --> 00:16:17,517
The mass production of products
In huge factories.
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00:16:17,517 --> 00:16:20,620
Industry's next revolution
Was automation,
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00:16:20,620 --> 00:16:24,551
Made possible
By computer technology.
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00:16:24,551 --> 00:16:26,448
By the 1970s,
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00:16:26,448 --> 00:16:30,379
Two centuries after the start
Of the industrial revolution,
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00:16:30,379 --> 00:16:34,758
Robots began replacing humans
On the production lines.
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00:20:40,448 --> 00:20:43,448
--captions by vitac--
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