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--captions by vitac--
Www.Vitac.Com
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Captions paid for by
Discovery communications, llc
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Narrator:
Today on "How it's made"...
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00:00:26,241 --> 00:00:27,965
...Curling stones...
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...Refrigerators...
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...Aluminum baseball bats...
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...And opalescent glass.
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The sport of curling
Is a combination
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Of shuffleboard, billiards,
And bowling on ice.
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Players aim a large stone
At a target
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00:01:01,344 --> 00:01:04,000
While trying to knock
The opponents' stones
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Away from the target.
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As the stone
Glides along the ice,
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Team members sweep brooms
In its path
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To control
Its speed and trajectory.
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Curling stones
Are made of granite,
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00:01:20,000 --> 00:01:22,206
But only two quarries
In the world --
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One in wales
And one in scotland --
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Produce the unique type
Of granite that's required,
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A fine grain and free of quartz.
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This unique stone
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Has three times the impact
Resistance of regular granite.
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The quarry tries to avoid
Traditional blast mining
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Because that fractures
The stone.
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Instead, they locate flaws
In the rock face
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And pry chunks off of it
With an excavator.
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This chunk weighs about 20 tons
And is the size of a small car.
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00:02:02,310 --> 00:02:05,896
The next step is to divide it
Into more manageable slabs
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Using a thick cable cutter
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With abrasive rings
Made of diamond particles.
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A large pulley system
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Moves the cable against the rock
At high speed,
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And the diamonds slowly wear
Through the granite.
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Avoiding flaws and weak points,
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00:02:31,103 --> 00:02:33,586
Workers trace circles
The size of curling stones
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On the best-quality areas.
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The cut slab then moves
Inside the quarry building,
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Where this core drill's
Diamond cutters
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Bore right through the slab,
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Excising a blank that
Will become a curling stone.
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The blanks weigh
Almost 60 pounds apiece.
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Workers lift them out with an
Industrial-strength suction cup
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Then transfer them
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To a container bound for a
Curling-stone factory in canada.
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There, a drill bores a channel
A little over a half-inch wide
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Right through the center.
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This is for attaching
The curling stone's handle.
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00:03:12,793 --> 00:03:15,689
But that's still a long way off.
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First, this machine
Has to carve the blank
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00:03:18,241 --> 00:03:20,310
Into the shape
Of a curling stone.
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The machine's curved arm
Is lined with diamond cutters.
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It shapes half the stone,
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Then workers flip the blank over
So it can finish the other half.
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The next machine
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Carves out a pocket
In the bottom of the stone.
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This will hold
A high-resistance insert
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Of extra-fine-grain
Scottish granite
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That will extend
The curling stone's life.
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After lining the pocket
With epoxy,
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The insert is positioned.
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A hydraulic press
Expels any trapped air
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And holds the insert in place
Until it firmly bonds.
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Next, a grinding machine,
Following a template,
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Makes a center cup in both
The top and bottom of the stone.
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Curlers can attach the handle
To either cup,
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Depending
On which granite surface
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They want gliding on the ice.
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Workers bolt the stone
To a spinning polisher
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And buff the surface
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With five progressively finer
Grades of diamond abrasive pads.
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Then they blast the side
With tiny glass beads.
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This pits the surface to better
Distribute impact force,
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Preventing the side
From chipping
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As it strikes other stones.
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Running the top and bottom
Over coarse sandpaper
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Gives the stone more traction
On ice.
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The finished curling stone
Weighs in at 40 pounds.
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The factory
Molds the stone's handle
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From durable
Impact-resistant plastic.
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This computer-guided
Engraving machine
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Can embellish it
With any name or logo.
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Paint is applied
To the recessed areas
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To make the lettering or design
Stand out.
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Finally, the finished handle
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Is bolted through that
Center hole drilled earlier.
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From the quarry
To the factory to the ice,
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This beautifully crafted curling
Stone is ready for competition.
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When we return...
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The cold, hard truth
About refrigerators.
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Narrator: before refrigeration,
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People stored foods in
Underground cellars or shacks
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Filled with snow and ice.
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Then in the early 1900s,
A french inventor developed
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The first machine to cool
And preserve foods at home.
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The modern refrigerator
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Comes in countless styles,
Sizes, and colors.
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Manufacturing begins
With coiled sheets of steel.
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Just one of these coils produces
Hundreds of fridge exteriors.
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The interiors are made
From rust-resistant aluminum
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Lined with an acrylic shell.
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A shearing machine
Slices the steel into pieces
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For the exterior top,
Back, and sides.
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Then each one goes
Into a computerized punch press
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That makes the holes
For running various wires.
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A brake press forces the steel
Against a forming die
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To create edges.
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00:07:06,206 --> 00:07:07,620
Next, workers place
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00:07:07,724 --> 00:07:09,965
The pieces of
The refrigerator's outer shell
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In an assembly jig, which
Holds them firmly together.
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00:07:18,448 --> 00:07:20,310
Now for the fridge's interior.
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A vacuum-forming machine
Heats a sheet of plastic
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And shapes it
Against an aluminum mold.
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Then a router carves off
All the excess plastic.
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The freezer half
Of the refrigerator
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Slides perfectly
Into the metal outer shell,
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And the fridge side
Follows.
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Copper tubes,
Filled with heated gas,
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Are laid along the outer edge
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Where the door
Contacts the fridge.
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The gas prevents
Moisture buildup.
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A precut face frame
Goes onto the assembly.
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Then foam is injected
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Into the cavity between the
Interior and exterior shells.
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00:08:02,758 --> 00:08:06,103
This foam not only insulates
The refrigerator
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But gives it
Structural rigidity, as well.
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This evaporator plays a key role
In keeping things cool.
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00:08:16,310 --> 00:08:19,413
It draws the heat out
Of the freezer and its contents.
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00:08:23,586 --> 00:08:27,310
Next, the electrical
Control panel goes into place.
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00:08:27,413 --> 00:08:29,551
It connects to a maze of wires
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00:08:29,655 --> 00:08:33,310
And, eventually,
A microprocessor.
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With the freezer side
Almost complete,
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The fridge side
Gets its evaporator.
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00:08:39,241 --> 00:08:41,724
Next comes
The refrigerator doors.
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00:08:43,827 --> 00:08:46,000
Two compressors
Pump fluid and gas
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Through
The various tubes inside.
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00:08:48,344 --> 00:08:50,655
This component,
Called the radiator,
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Dissipates the heat
Collected from the food.
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00:08:58,896 --> 00:09:01,344
Workers attach
The expansion valves.
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00:09:01,448 --> 00:09:04,172
These allow
The pressurized liquid coolant
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00:09:04,275 --> 00:09:05,862
To expand into a cold gas
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00:09:05,965 --> 00:09:09,103
That circulates through
The refrigerator's tubes.
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00:09:12,827 --> 00:09:15,758
Copper tubes are soldered
To the compressor.
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Later, they'll be filled
With refrigerant.
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00:09:18,724 --> 00:09:20,655
Temporary quick-connect valves
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00:09:20,758 --> 00:09:23,724
Allow the system
To be charged with inert gas
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00:09:23,827 --> 00:09:25,620
To check for any leaks.
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00:09:25,724 --> 00:09:29,551
The fill hoses are connected,
And the gas blows in.
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00:09:33,310 --> 00:09:35,172
Inspectors use this wand
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00:09:35,275 --> 00:09:37,689
To check the tubes
For escaping gas.
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If there's a leak,
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The gauge spikes
Out of the specified range.
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Refrigeration occurs as cold gas
In the evaporator coils
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00:09:50,551 --> 00:09:53,310
Pulls heat energy
From inside the fridge.
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The compressor then changes
The gas back to a liquid
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00:09:56,931 --> 00:10:00,103
While the radiator
Dissipates the collected heat.
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00:10:00,206 --> 00:10:03,758
The expansion valve turns
The liquid back into a cold gas,
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00:10:03,862 --> 00:10:06,517
And the cycle repeats.
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00:10:06,620 --> 00:10:08,620
With a charging gun,
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00:10:08,724 --> 00:10:11,724
Workers inject refrigerant gas
Into each tube
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00:10:11,827 --> 00:10:14,379
Then weld
The ends of the tube shut.
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00:10:20,206 --> 00:10:22,172
Now for the finishing touches,
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Starting
With the refrigerator handles.
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Drawers for fruits and
Vegetables slide right in --
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00:10:28,689 --> 00:10:31,965
So do the rest of the premade
Shelves and compartments.
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00:10:38,034 --> 00:10:42,000
Finally, an adhesive logo
Goes onto the door.
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00:10:46,137 --> 00:10:50,103
Built-in, stand-alone,
Double-door, or traditional,
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The refrigerator keeps our food
Fresh and cool,
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Just the way we like it.
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00:10:56,896 --> 00:10:58,103
Up next...
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A factory that tries to hit
A home run every time.
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Narrator:
On today's baseball diamonds,
The ping of the aluminum bat
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Is rivaling the crack
Of its wooden predecessor.
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00:11:13,103 --> 00:11:16,103
The pros still use
Traditional wood,
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00:11:16,206 --> 00:11:21,000
But outside the major leagues,
The metal bat is a definite hit.
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Lightweight and durable,
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00:11:30,793 --> 00:11:34,344
The metal bat has some
Definite advantages over wood.
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00:11:34,448 --> 00:11:38,310
Production begins with
Aircraft-grade aluminum rods.
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These rods are sliced into
Short chunks called blanks.
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00:11:46,241 --> 00:11:50,758
The blanks are loaded into a
Lathe with a computerized drill.
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00:11:55,275 --> 00:11:59,172
The drill tunnels through the
Center of the blank as it spins.
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00:12:05,896 --> 00:12:10,137
Then the blank undergoes
What's called impact extrusion.
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With 300 tons of force,
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00:12:12,413 --> 00:12:15,413
A shaping tool bores
Into the hole in the blank,
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00:12:15,517 --> 00:12:17,965
Stretching it to more than
Twice its length
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00:12:18,068 --> 00:12:21,551
And giving it the basic taper
Of a baseball bat.
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00:12:24,689 --> 00:12:27,034
The stretched bat blanks
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00:12:27,137 --> 00:12:30,172
Now tumble into
A big, perforated drum.
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00:12:32,310 --> 00:12:35,862
The drum is lowered
Into a tank of soapy water.
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00:12:38,172 --> 00:12:40,793
As it turns,
Water flows through its holes,
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00:12:40,896 --> 00:12:44,448
Washing away any oily residue.
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00:12:46,344 --> 00:12:48,724
And now,
For a real heavy hitter.
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00:12:48,827 --> 00:12:52,034
This forming tool
Delivers 400-ton punch
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00:12:52,137 --> 00:12:54,275
Through the center
Of the bat blank.
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00:12:54,379 --> 00:12:56,275
The aluminum
Stretches around the tool
195
00:12:56,379 --> 00:13:00,000
To the full length
And shape of a baseball bat.
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00:13:07,448 --> 00:13:08,896
A technician measures the bat
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00:13:09,000 --> 00:13:11,310
To confirm that
It's completely straight.
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00:13:12,620 --> 00:13:14,068
If it's not,
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00:13:14,172 --> 00:13:17,724
She applies a little hydraulic
Pressure to bend it into shape.
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00:13:17,827 --> 00:13:21,896
This is a critical step because
Even a slightly crooked bat
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00:13:22,000 --> 00:13:25,137
Could throw the player
Off his or her game.
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00:13:34,655 --> 00:13:39,620
Next, the bat goes into
Another computerized lathe.
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00:13:39,724 --> 00:13:41,551
As it spins,
204
00:13:41,655 --> 00:13:45,827
A blade lops off the bat's end,
Cutting it to size.
205
00:13:45,931 --> 00:13:50,000
Another tool threads the inside
For the endcap.
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00:13:54,931 --> 00:13:57,482
The bat is locked
Into a holding device,
207
00:13:57,586 --> 00:14:00,068
And a circular saw
Trims the handle end.
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00:14:07,000 --> 00:14:09,275
Now that the bat
Has been correctly sized,
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00:14:09,379 --> 00:14:12,379
It's time
For a vigorous sanding.
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00:14:12,482 --> 00:14:14,275
This gets rid
Of any small defects
211
00:14:14,379 --> 00:14:17,758
And roughs up the surface
So paint will stick to it.
212
00:14:26,931 --> 00:14:28,758
They use heavy-duty paint
213
00:14:28,862 --> 00:14:32,965
Because baseball bats have to
Stand up to a lot of abuse.
214
00:14:38,379 --> 00:14:40,862
The sanded bats go into
A silk-screen machine
215
00:14:40,965 --> 00:14:43,241
That applies the trademark.
216
00:14:48,793 --> 00:14:52,172
Then it's
Over to the decal department.
217
00:14:53,517 --> 00:14:55,448
The decals
Are dipped into a solution
218
00:14:55,551 --> 00:14:58,551
That activates the glue,
219
00:14:58,655 --> 00:15:00,758
Then they're stuck into place.
220
00:15:07,206 --> 00:15:09,379
Now it's
Back under the paint gun
221
00:15:09,482 --> 00:15:12,068
For a clear coat
Of polyurethane.
222
00:15:16,793 --> 00:15:21,448
The plastic endcap is press-fit
Into the hollow barrel.
223
00:15:26,068 --> 00:15:29,103
An aluminum knob
Slides onto the handle end,
224
00:15:29,206 --> 00:15:31,689
And the assembly goes into
An automated welding machine
225
00:15:31,793 --> 00:15:33,000
That fuses them together.
226
00:15:40,275 --> 00:15:41,551
Now for the grip.
227
00:15:41,655 --> 00:15:44,896
Synthetic leather
Is wrapped around the handle
228
00:15:45,000 --> 00:15:47,586
To provide a nonslip surface.
229
00:15:47,689 --> 00:15:51,344
And a little vinyl tape
Finishes the edge.
230
00:15:52,689 --> 00:15:54,931
From a solid little chunk
Of aluminum
231
00:15:55,034 --> 00:15:57,275
To a hollow metal baseball bat,
232
00:15:57,379 --> 00:16:01,344
This powerhouse is ready
To hit one out of the park.
233
00:16:04,862 --> 00:16:05,827
Coming up...
234
00:16:05,931 --> 00:16:09,068
The hot secrets
Behind opalescent glass.
235
00:16:14,827 --> 00:16:16,689
Narrator: glassmaking dates back
More than 40 centuries.
236
00:16:16,793 --> 00:16:18,241
But in the late 1800s,
237
00:16:18,344 --> 00:16:20,827
Glassmakers
Created something new --
238
00:16:20,931 --> 00:16:24,172
Glass that was both milky
And translucent.
239
00:16:24,275 --> 00:16:26,586
They called it opalescent glass.
240
00:16:26,689 --> 00:16:29,103
Like its namesake,
The opal gemstone,
241
00:16:29,206 --> 00:16:32,965
Its beauty lies in the way
It magically catches the light.
242
00:16:38,344 --> 00:16:41,344
Opalescent glass
Is a semitransparent glass
243
00:16:41,448 --> 00:16:44,931
In either a solid color
Or a swirling mix of hues.
244
00:16:46,275 --> 00:16:48,793
Glass makers create it
By melting minerals,
245
00:16:48,896 --> 00:16:50,931
Including silica sand...
246
00:16:52,655 --> 00:16:54,724
...Soda ash...
247
00:16:56,965 --> 00:16:58,482
...Dolomite...
248
00:17:00,379 --> 00:17:02,206
...Limestone...
249
00:17:03,965 --> 00:17:06,482
...And fluorspar.
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00:17:06,586 --> 00:17:10,068
Adding recycled glass helps
Speed up the melting process
251
00:17:10,172 --> 00:17:13,206
And stretches costly
Raw materials further.
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00:17:13,310 --> 00:17:17,103
The mix
Is colored with pigments,
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In this case, cobalt oxide,
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Which gives
A distinctive blue tint.
255
00:17:26,965 --> 00:17:29,931
A hoist then lifts
The raw ingredients called batch
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00:17:30,034 --> 00:17:31,655
To a double-chambered mixer.
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00:17:31,758 --> 00:17:34,482
Ingredients flow
From end to end between them,
258
00:17:34,586 --> 00:17:37,068
Thoroughly blending the batch.
259
00:17:46,620 --> 00:17:50,758
The blended batch now goes
Via wagon to the beehive --
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00:17:50,862 --> 00:17:53,965
A furnace that contains
12 ceramic pots.
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00:17:54,068 --> 00:17:57,931
The furnace worker
Shovels the batch into a pot
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00:17:58,034 --> 00:18:01,034
To melt at a searing
2,600 degrees fahrenheit.
263
00:18:02,931 --> 00:18:05,620
He pushes any spills
Back into the pot.
264
00:18:05,724 --> 00:18:08,448
Then to control
The temperature inside,
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00:18:08,551 --> 00:18:11,103
Closes up the pot's mouth.
266
00:18:14,793 --> 00:18:15,862
24 hours later,
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00:18:15,965 --> 00:18:18,896
Workers scoop out
The glowing molten glass.
268
00:18:19,000 --> 00:18:22,689
With only seconds to spare,
They hurry to the mixing table,
269
00:18:22,793 --> 00:18:24,517
Keeping the glass in motion
270
00:18:24,620 --> 00:18:27,655
To prevent it from cooling
Unevenly on the way.
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00:18:27,758 --> 00:18:31,379
It's critical they cool off
The ladles between each use
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00:18:31,482 --> 00:18:35,275
Or the next scoop of glass will
Adhere to the ladle's surface.
273
00:18:35,379 --> 00:18:38,448
The ladles they use
Vary in size,
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00:18:38,551 --> 00:18:42,827
Holding between 4 and 40 pounds
Of molten glass.
275
00:18:46,551 --> 00:18:49,655
Workers pour as many as
Five different ladles at once
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00:18:49,758 --> 00:18:52,103
To make a single color.
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00:18:52,206 --> 00:18:56,241
The mixing table
Is where the magic happens.
278
00:18:56,344 --> 00:18:59,827
The table worker picks up one
Gather of burning molten glass,
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00:18:59,931 --> 00:19:01,586
Then another,
280
00:19:01,689 --> 00:19:05,482
Then skillfully blends them
Together using a steel fork.
281
00:19:05,586 --> 00:19:08,206
He then flips the molten glass
Into a rolling machine,
282
00:19:08,310 --> 00:19:12,000
Evening it out as it squeezes
Through the rollers.
283
00:19:14,344 --> 00:19:16,413
Out comes a sheet
About 6 feet long
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00:19:16,517 --> 00:19:18,034
And 1/8th of an inch thick.
285
00:19:20,896 --> 00:19:24,000
Every 90 seconds,
Workers fill their ladles
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00:19:24,103 --> 00:19:27,448
With 2,000 degree fahrenheit
Molten glass.
287
00:19:27,551 --> 00:19:31,448
Mixing it on the table helps
Cool it and blend the colors.
288
00:19:40,137 --> 00:19:42,758
The table worker
Separates the glass sheet
289
00:19:42,862 --> 00:19:44,275
From the table surface,
290
00:19:44,379 --> 00:19:46,344
Forcing out any
Trapped air bubbles
291
00:19:46,448 --> 00:19:49,206
And further cooling the glass.
292
00:19:50,965 --> 00:19:53,103
The sheet now goes
Into a lehr --
293
00:19:53,206 --> 00:19:55,103
An oven that hardens the glass,
294
00:19:55,206 --> 00:19:58,586
Then cools it evenly
To prevent cracking.
295
00:19:58,689 --> 00:20:01,689
From there,
It's on to the trimming table.
296
00:20:01,793 --> 00:20:04,758
Workers wear protective clothing
And thick gloves
297
00:20:04,862 --> 00:20:09,137
To handle the razor-sharp edges
Still hot to the touch.
298
00:20:09,241 --> 00:20:12,724
Cutting the glass sheets
Is a delicate, two-person job.
299
00:20:12,827 --> 00:20:14,551
They must work in sync
300
00:20:14,655 --> 00:20:17,413
To keep pace with the sheets
That keep on coming.
301
00:20:17,517 --> 00:20:21,931
A single pot produces
About 25 sheets over 24 hours.
302
00:20:22,034 --> 00:20:26,620
That's 300 sheets a day
From just one 12-pot furnace.
303
00:20:28,379 --> 00:20:33,000
Using a carbide-tipped cutter,
The workers score the glass,
304
00:20:33,103 --> 00:20:37,931
Then snap apart the pieces --
Standard 32-inch square sheets.
305
00:20:46,000 --> 00:20:49,965
They set aside the excess glass
To remelt in a new batch.
306
00:20:52,275 --> 00:20:55,103
Finally, the sheets
Are loaded into crates
307
00:20:55,206 --> 00:20:57,965
For shipment all over the world.
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00:20:59,655 --> 00:21:02,068
Just look how artists
Use opalescent glass
309
00:21:02,172 --> 00:21:05,793
To create a feast of pattern,
Color, and light.
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00:21:07,655 --> 00:21:11,206
Like a painting,
Only far more fragile.
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00:21:12,965 --> 00:21:14,827
If you have any comments
About the show,
312
00:21:14,931 --> 00:21:17,551
Or if you'd like to suggest
Topics for future shows,
313
00:21:17,655 --> 00:21:19,551
Drop us a line at...
25193
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