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Narrator:
AN 1880s INVENTION,
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THE CAST-IRON TUB
WAS FIRST MARKETED IN AMERICA
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00:00:58,172 --> 00:01:00,655
AS A HORSE TROUGH
AND A HOG SCALDER,
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00:01:00,655 --> 00:01:03,172
WHICH COULD ALSO SERVE
AS A BATHTUB.
5
00:01:03,172 --> 00:01:06,655
IT WAS SOON MORE POPULAR IN
THE BATHROOM THAN THE BARNYARD.
6
00:01:06,655 --> 00:01:08,448
IT'S HEAT-RETAINING PROPERTIES
7
00:01:08,448 --> 00:01:11,379
MADE A LONG AND LUXURIOUS SOAK
POSSIBLE.
8
00:01:15,172 --> 00:01:18,103
THE CAST-IRON TUB
IS ONE INVENTION
9
00:01:18,103 --> 00:01:20,068
THAT'S GOT A LOT OF PEOPLE
IN HOT WATER,
10
00:01:20,068 --> 00:01:22,655
AND THAT'S WHAT PEOPLE LIKE
ABOUT IT.
11
00:01:24,965 --> 00:01:28,517
TODAY, THEY MAKE CAST-IRON TUBS
FROM SCRAP METAL --
12
00:01:28,517 --> 00:01:31,241
THINGS
LIKE OLD HEATING RADIATORS,
13
00:01:31,241 --> 00:01:35,517
WATER PIPES, MANHOLE COVERS,
AND EVEN SOME CAR PARTS.
14
00:01:38,620 --> 00:01:40,034
RECYCLING SCRAP IRON
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00:01:40,034 --> 00:01:43,344
IS MORE ENERGY EFFICIENT
AND CHEAPER THAN MINING IT.
16
00:01:45,310 --> 00:01:48,034
A POWERFUL MAGNET
AT THE END OF A CRANE ARM
17
00:01:48,034 --> 00:01:50,517
LIFTS THE HEAVY IRON
FROM THE SCRAP HEAP
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00:01:50,517 --> 00:01:51,620
AND TRANSFERS IT
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00:01:51,620 --> 00:01:54,344
TO BIG TRAYS
KNOWN AS CHARGING PANS.
20
00:01:56,344 --> 00:01:59,793
THE CHARGING PANS DELIVER
THE SCRAP TO A CENTER TROUGH.
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00:01:59,793 --> 00:02:01,344
THIS TROUGH IS A SCALE.
22
00:02:01,344 --> 00:02:04,448
IT WEIGHS THE SCRAP
AND RELEASES IT TO A CONVEYER.
23
00:02:08,172 --> 00:02:11,137
THE SCRAP HEADS
INTO THE BATHTUB FACTORY.
24
00:02:13,413 --> 00:02:15,068
INSIDE, IT FLOWS DIRECTLY
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00:02:15,068 --> 00:02:17,965
INTO AN ENORMOUS
ELECTRIC INDUCTION FURNACE
26
00:02:17,965 --> 00:02:22,689
HEATED
TO MORE THAN 2,500° FAHRENHEIT.
27
00:02:22,689 --> 00:02:27,310
THE SCRAP IRON MELTS
INTO A POOL OF LIQUID METAL.
28
00:02:29,413 --> 00:02:31,758
THEY RUN THIS FURNACE
AROUND THE CLOCK,
29
00:02:31,758 --> 00:02:33,793
AND IT'S ALWAYS TWO-THIRDS FULL
30
00:02:33,793 --> 00:02:36,241
SO THAT NEWLY-ADDED SCRAP
MELTS QUICKLY.
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00:02:38,413 --> 00:02:41,655
HUGE HYDRAULIC CYLINDERS TIP
THE FURNACE FORWARD.
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00:02:41,655 --> 00:02:44,413
THE MOLTEN IRON FLOWS
INTO A LADLE.
33
00:02:51,379 --> 00:02:53,103
AN OVERHEAD TROLLEY
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00:02:53,103 --> 00:02:55,758
CARRIES THE LADLE BRIMMING
WITH THE HOT LIQUID METAL
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00:02:55,758 --> 00:02:58,379
TO A HOLDING FURNACE
WHICH MAINTAINS ITS TEMPERATURE
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00:02:58,379 --> 00:03:00,965
UNTIL THE NEXT STEP.
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00:03:00,965 --> 00:03:02,620
THEY'RE NOW READY
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00:03:02,620 --> 00:03:04,896
TO MAKE A TWO-PART CASTING MOLD
FROM SAND
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00:03:04,896 --> 00:03:06,724
USING STEEL TUB PATTERNS.
40
00:03:06,724 --> 00:03:10,413
TO MAKE ONE HALF OF THE MOLD,
THEY FILL A TUB PATTERN
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00:03:10,413 --> 00:03:12,965
WITH A MIX
OF MOIST SAND AND CLAY.
42
00:03:12,965 --> 00:03:15,344
HYDRAULIC RAMS PACK IT DOWN,
43
00:03:15,344 --> 00:03:17,137
AND THE MIX COMPACTS
44
00:03:17,137 --> 00:03:19,068
AND TAKES THE SHAPE
OF THE PATTERN.
45
00:03:19,068 --> 00:03:20,551
THE CLAY IS THE BONDING AGENT
46
00:03:20,551 --> 00:03:23,586
THAT CAUSES
THE MIX TO HOLD THE SHAPE.
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00:03:23,586 --> 00:03:24,862
ONCE THE RAMS RETRACT,
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00:03:24,862 --> 00:03:27,103
THE MOLD TAKES A TRIP
UNDER SOME BLADES
49
00:03:27,103 --> 00:03:30,482
THAT SCRAPE OFF THE EXCESS SAND.
50
00:03:30,482 --> 00:03:33,137
MACHINERY THEN LIFTS THIS HALF
OF THE SAND MOLD
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00:03:33,137 --> 00:03:35,931
OUT OF THE STEEL PATTERN
AND TRANSFERS IT
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00:03:35,931 --> 00:03:38,517
TO THE OTHER HALF OF THE MOLD
PREPARED EARLIER.
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00:03:41,275 --> 00:03:43,827
THE TWO BATHTUB MOLDS
NOW COME TOGETHER,
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00:03:43,827 --> 00:03:46,689
LEAVING A SMALL GAP
BETWEEN THEM.
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00:03:49,000 --> 00:03:51,172
THE MOLTEN IRON,
WHICH HAS BEEN TRANSFERRED
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00:03:51,172 --> 00:03:52,724
TO AN AUTOMATIC POURING SYSTEM,
57
00:03:52,724 --> 00:03:55,275
FLOWS INTO PORTALS
IN THE TOP OF THE MOLD
58
00:03:55,275 --> 00:03:57,586
AND INTO THE GAP AT THE CENTER.
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00:03:57,586 --> 00:04:00,379
THE BATHTUB MOLDS
THEN MOVE TO A COOLING LINE,
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00:04:00,379 --> 00:04:03,172
AND AFTER CHILLING HERE
FOR ABOUT 20 MINUTES,
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00:04:03,172 --> 00:04:05,689
THE IRON INSIDE SOLIDIFIES.
62
00:04:05,689 --> 00:04:10,206
THEN, IT'S INTO A SHAKER DEVICE
THAT BREAKS APART THE SAND MOLD,
63
00:04:10,206 --> 00:04:13,310
REVEALING
THE NEWLY CAST IRON BATHTUB.
64
00:04:16,310 --> 00:04:19,965
A ROBOT RETRIEVES THE BATHTUB
AND STACKS IT.
65
00:04:23,965 --> 00:04:25,517
NEXT, AN EMPLOYEE
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00:04:25,517 --> 00:04:28,206
SPRAYS SPECIALLY-FORMULATED
GLASS POWDER
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00:04:28,206 --> 00:04:29,379
ONTO THE TUB.
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00:04:29,379 --> 00:04:31,793
IT'S AN UNDERCOAT
FOR THE ENAMEL FINISH.
69
00:04:31,793 --> 00:04:34,827
THEY BAKE THE TUB
UNTIL IT'S RED-HOT.
70
00:04:34,827 --> 00:04:36,275
IN THE HEAT,
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00:04:36,275 --> 00:04:40,448
THE GLASS POWDER MELTS
AND ADHERES TO THE IRON TUB.
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00:04:40,448 --> 00:04:43,172
A HYDRAULIC DEVICE
CALLED A MANIPULATOR
73
00:04:43,172 --> 00:04:45,137
SETS THE TUB ON A PEDESTAL.
74
00:04:45,137 --> 00:04:46,931
THE PEDESTAL SWIVELS
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00:04:46,931 --> 00:04:50,137
AS THEY APPLY
TWO MORE GROUND-GLASS LAYERS.
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00:04:50,137 --> 00:04:52,655
THESE ARE THE ENAMEL TOPCOATS.
77
00:04:52,655 --> 00:04:56,448
ON CONTACT, THE GLASS MIXTURE
MELTS ONTO THE UNDERCOAT.
78
00:04:56,448 --> 00:04:58,931
THE LAYERS OF GLASS
FORM A PERMANENT BOND
79
00:04:58,931 --> 00:05:00,344
WITH THE IRON CASTING.
80
00:05:02,172 --> 00:05:04,172
BETWEEN COATS, THE TUB COOLS,
81
00:05:04,172 --> 00:05:07,655
AND THEY SEND IT BACK
INTO THE FURNACE FOR A REHEAT.
82
00:05:09,379 --> 00:05:12,689
THEY PLACE A MASK
IN THE BASE OF THE ENAMEL TUB.
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00:05:12,689 --> 00:05:15,275
THE MASK IS LIKE A STENCIL.
84
00:05:15,275 --> 00:05:18,689
A ROBOT BLASTS FINE
ALUMINA-OXIDE PARTICLES
85
00:05:18,689 --> 00:05:21,206
INTO THE OPEN AREAS OF THE MASK.
86
00:05:21,206 --> 00:05:24,103
THIS ETCHES AN ABRASIVE FINISH,
87
00:05:24,103 --> 00:05:27,517
LEAVING A SUBTLE PATTERN
ON THE SURFACE OF THE BATHTUB.
88
00:05:27,517 --> 00:05:29,172
IT CREATES VISUAL INTEREST
89
00:05:29,172 --> 00:05:33,310
AND ALSO PROVIDES
A NON-SLIP SURFACE.
90
00:05:33,310 --> 00:05:38,137
THE MASKS COME IN A VARIETY
OF PATTERNS FOR DIFFERENT LOOKS.
91
00:05:38,137 --> 00:05:39,965
WHETHER IT'S A MODERN DESIGN
92
00:05:39,965 --> 00:05:42,275
OR THE TRADITIONAL
CLAW-FOOT ONE,
93
00:05:42,275 --> 00:05:46,758
THESE CAST-IRON TUBS SHOULD HAVE
NO PROBLEM FINDING A HOME.
94
00:06:00,965 --> 00:06:03,931
Narrator: THE HOPI,
A NATIVE AMERICAN TRIBE
95
00:06:03,931 --> 00:06:06,689
LIVING PRIMARILY
IN NORTHEASTERN ARIZONA,
96
00:06:06,689 --> 00:06:08,655
ARE KNOWN FOR CARVING KACHINAS,
97
00:06:08,655 --> 00:06:11,068
WOODEN DOLLS
REPRESENTING DEITIES,
98
00:06:11,068 --> 00:06:14,241
ELEMENTS IN NATURE,
OR THE SPIRITS OF ANCESTORS.
99
00:06:14,241 --> 00:06:16,827
THEY ARE TRADITIONALLY PRESENTED
IN A DANCE CEREMONY
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00:06:16,827 --> 00:06:18,862
TO THE GIRLS OF THE COMMUNITY.
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HOPI KACHINA DOLLS
ARE CHERISHED FAMILY KEEPSAKES
102
00:06:25,000 --> 00:06:29,034
DESIGNED TO TEACH HOPI CHILDREN
ABOUT THE DEITIES AND SPIRITS
103
00:06:29,034 --> 00:06:32,103
CENTRAL
TO THEIR ABORIGINAL TRADITIONS.
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00:06:32,103 --> 00:06:34,172
BESIDES CEREMONIAL PURPOSES,
105
00:06:34,172 --> 00:06:37,172
MANY HOPI CARVERS PRODUCE
KACHINA DOLLS
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00:06:37,172 --> 00:06:40,034
FOR SALE
TO NATIVE ART ENTHUSIASTS.
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00:06:43,517 --> 00:06:47,862
THE CARVER USES
KNIVES OF DIFFERENT SIZES,
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00:06:47,862 --> 00:06:50,448
SHARPENING THE STEEL BLADES
AFTER EVERY 10 OR 15 MINUTES
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00:06:50,448 --> 00:06:54,206
TO PREVENT DULLING.
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00:06:54,206 --> 00:06:58,137
KACHINA DOLLS ARE TRADITIONALLY
MADE OF COTTONWOOD --
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00:06:58,137 --> 00:07:01,655
NOT FROM THE TREE'S BRANCH,
BUT FROM ITS ROOT.
112
00:07:01,655 --> 00:07:07,068
THE CARVER BEGINS BY SHAVING OFF
THE THIN OUTER BARK.
113
00:07:07,068 --> 00:07:09,965
WITH A STRAIGHT CUT
FROM ONE SIDE TO THE OTHER,
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00:07:09,965 --> 00:07:12,241
HE SHAPES
A BIT OF THE SINGLE FEATHER
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00:07:12,241 --> 00:07:14,896
WHICH WILL ADORN THE TOP
OF THIS DOLL'S HEAD.
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00:07:18,103 --> 00:07:20,379
HE MAKES
A SERIES OF VERTICAL CUTS
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00:07:20,379 --> 00:07:22,689
TO FORM THE FACE AND HAIRLINE.
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00:07:24,379 --> 00:07:27,724
HE CONTINUES CARVING
THE HEAD FORM,
119
00:07:27,724 --> 00:07:29,758
THEN, WITH A WOOD-BURNING TOOL,
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00:07:29,758 --> 00:07:32,517
BURNS IN THE SQUARE OUTLINE
OF THE FACE.
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00:07:32,517 --> 00:07:35,448
NOW HE SHAVES AWAY WOOD
ABOVE AND BELOW
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00:07:35,448 --> 00:07:38,448
TO MAKE THE FACE PROTRUDE.
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00:07:38,448 --> 00:07:41,862
HE FORMS THE FACE
IN MORE DETAIL...
124
00:07:44,793 --> 00:07:47,689
...THEN PICKS UP
THE WOOD-BURNING TOOL AGAIN,
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00:07:47,689 --> 00:07:50,137
THIS TIME TO DELINEATE
THE NECKLINE...
126
00:07:52,172 --> 00:07:54,931
...AND THE DOLL'S ROBE.
127
00:08:02,413 --> 00:08:03,758
BACK TO CARVING.
128
00:08:03,758 --> 00:08:05,724
NOW, WITH UPWARD STROKES,
129
00:08:05,724 --> 00:08:11,310
HE SHAVES OFF WOOD
TO SHAPE THE NECKLINE.
130
00:08:11,310 --> 00:08:12,724
HE TAKES A LARGER KNIFE
131
00:08:12,724 --> 00:08:14,793
AND REMOVES
BIGGER PIECES OF WOOD
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00:08:14,793 --> 00:08:17,413
TO FINISH FORMING
THE HEAD FEATHER.
133
00:08:17,413 --> 00:08:19,344
NOW HE SANDS THE WOOD
134
00:08:19,344 --> 00:08:21,206
WITH PROGRESSIVELY FINER
SANDPAPERS
135
00:08:21,206 --> 00:08:24,206
TO REMOVE ALL THE CUT MARKS
LEFT BY HIS KNIVES
136
00:08:24,206 --> 00:08:26,379
AND TO REFINE THE DOLL'S SHAPE.
137
00:08:26,379 --> 00:08:28,862
WITH THE DOLL
PERFECTLY FORMED NOW,
138
00:08:28,862 --> 00:08:31,758
IT'S TIME FOR THE DETAILS
AND DECORATIONS.
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00:08:31,758 --> 00:08:34,965
FIRST, HE SKETCHES IT ALL OUT
IN PENCIL...
140
00:08:37,827 --> 00:08:41,482
...THEN RUNS THE WOOD-BURNING
TOOL ALONG THE LINES.
141
00:08:46,827 --> 00:08:50,275
HE DECORATES THE BODY,
142
00:08:50,275 --> 00:08:54,068
THEN MOVES ON TO THE DOLL'S HAIR
AND FACIAL FEATURES.
143
00:08:54,068 --> 00:08:57,551
IT'S THESE DETAILS
THAT BRING THE DOLL ALIVE.
144
00:09:21,310 --> 00:09:24,413
WHAT WAS A SIMPLE AND ORDINARY
COTTONWOOD TREE ROOT
145
00:09:24,413 --> 00:09:27,448
HAS GONE THROUGH CARVING,
SANDING, AND BURNING
146
00:09:27,448 --> 00:09:30,965
TO BECOME
AN ALMOST-FINISHED KACHINA DOLL.
147
00:09:30,965 --> 00:09:34,551
HE NOW COATS THE ENTIRE SURFACE
WITH CLEAR VARNISH.
148
00:09:34,551 --> 00:09:36,241
THIS SEALS THE WOOD
149
00:09:36,241 --> 00:09:40,000
TO PREVENT IT FROM ABSORBING
THE PAINT HE APPLIES NEXT.
150
00:09:40,000 --> 00:09:42,413
ABOUT 40 MINUTES LATER,
151
00:09:42,413 --> 00:09:45,413
THE VARNISH IS DRY
AND THE PAINTING CAN BEGIN.
152
00:09:45,413 --> 00:09:49,103
TRADITIONALLY, HOPI CARVERS
MADE PAINT FROM NATURAL PIGMENTS
153
00:09:49,103 --> 00:09:51,344
SUCH AS SAND, PLANTS,
AND BERRIES.
154
00:09:51,344 --> 00:09:56,655
TODAY'S CARVERS BUY
READY-MADE OILS OR ACRYLICS.
155
00:09:56,655 --> 00:09:59,103
THIS CARVER DILUTES
ACRYLIC PAINT WITH WATER
156
00:09:59,103 --> 00:10:00,413
TO MAKE IT TRANSPARENT.
157
00:10:00,413 --> 00:10:03,413
THIS ALLOWS THE NATURAL BEAUTY
OF THE WOOD GRAIN
158
00:10:03,413 --> 00:10:05,000
TO SHOW THROUGH THE COLOR.
159
00:10:09,724 --> 00:10:13,448
AFTER PAINTING, HE APPLIES
A COAT OF CLEAR VARNISH
160
00:10:13,448 --> 00:10:15,931
TO SEAL AND PROTECT THE SURFACE.
161
00:10:18,172 --> 00:10:22,137
SOME CARVERS HAVE MOVED IN A NEW
ARTISTIC DIRECTION -- BRONZE.
162
00:10:22,137 --> 00:10:26,827
THEY USE THEIR WOODEN KACHINA
DOLL TO PRODUCE A LATEX MOLD.
163
00:10:26,827 --> 00:10:30,275
THEN, WITH THIS MOLD,
CAST A WAX REPLICA.
164
00:10:30,275 --> 00:10:32,344
THEY DIP THE REPLICA
IN A SUBSTANCE
165
00:10:32,344 --> 00:10:34,724
THAT HARDENS
INTO A HEAT-RESISTANT SHELL.
166
00:10:34,724 --> 00:10:38,275
THEN, THEY PUT THE SHELL IN
A FURNACE TO MELT AWAY THE WAX.
167
00:10:38,275 --> 00:10:41,310
THIS LEAVES A CAVITY
IN THE SHAPE OF THE DOLL.
168
00:10:41,310 --> 00:10:44,172
THEY POOR MOLTEN BRONZE
INTO THE CAVITY,
169
00:10:44,172 --> 00:10:46,310
AND WHEN THE BRONZE
COOLS AND SOLIDIFIES,
170
00:10:46,310 --> 00:10:49,103
THEY BREAK THE SHELL
TO EXTRACT A BRONZE VERSION
171
00:10:49,103 --> 00:10:51,344
OF THEIR KACHINA DOLL.
172
00:10:51,344 --> 00:10:52,931
INSTEAD OF PAINTS,
173
00:10:52,931 --> 00:10:54,896
THEY APPLY CHEMICALS
THAT COLOR THE METAL --
174
00:10:54,896 --> 00:10:59,068
A MODERN TWIST
ON AN AGE-OLD HOPI ART.
175
00:11:08,482 --> 00:11:11,275
Narrator:
A MINE-TRUCK ENGINE IS A BEAST.
176
00:11:11,275 --> 00:11:14,517
THE MOST POWERFUL ONES PACK
A BRAWNY 24 CYLINDERS,
177
00:11:14,517 --> 00:11:17,758
GENERATING 4,200 HORSEPOWER.
178
00:11:17,758 --> 00:11:19,448
COMPARE THAT TO 200 HORSEPOWER
179
00:11:19,448 --> 00:11:21,827
FOR A MID-SIZED CAR
WITH SIX CYLINDERS.
180
00:11:21,827 --> 00:11:24,137
BUT WHEN THEY START
TO SHOW THE STRAIN,
181
00:11:24,137 --> 00:11:27,000
IT'S TIME FOR A TOTAL REBUILD.
182
00:11:29,448 --> 00:11:33,000
AFTER ABOUT 20,000 HOURS
OF HAULING HEAVY ROCK,
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00:11:33,000 --> 00:11:34,758
IT'S TIME FOR RENEWAL.
184
00:11:34,758 --> 00:11:38,172
MINE-TRUCK ENGINES
ARE ROUTINELY REBUILT --
185
00:11:38,172 --> 00:11:41,034
NOT JUST ONCE,
BUT NUMEROUS TIMES.
186
00:11:41,034 --> 00:11:44,137
IT'S CHEAPER
THAN BUYING A NEW ENGINE,
187
00:11:44,137 --> 00:11:46,586
AND IT SAVES PRECIOUS RESOURCES.
188
00:11:46,586 --> 00:11:50,413
EACH REBUILD
IS A MASSIVE UNDERTAKING --
189
00:11:50,413 --> 00:11:53,448
VIRTUALLY EVERY COMPONENT
OF THIS DIESEL ENGINE
190
00:11:53,448 --> 00:11:57,310
WILL BE REMANUFACTURED
OR REPLACED.
191
00:11:57,310 --> 00:11:59,758
AS THE TEAM DISMANTLES IT,
192
00:11:59,758 --> 00:12:03,103
THEY INSPECT EACH PART
FOR WEAR AND TEAR.
193
00:12:03,103 --> 00:12:06,620
THEY TAKE IT DOWN
TO THE IMMENSE CRANKSHAFT,
194
00:12:06,620 --> 00:12:10,103
THE HEART
OF THIS MINE-TRUCK ENGINE.
195
00:12:10,103 --> 00:12:12,551
WITH THE CRANKSHAFT REMOVED,
196
00:12:12,551 --> 00:12:17,068
THEY PULL THE LENGTHY CAMSHAFT
OUT OF THE CYLINDER BLOCK.
197
00:12:17,068 --> 00:12:19,655
WITH THE ENGINE NOW IN PIECES,
198
00:12:19,655 --> 00:12:21,862
THEY CLEAN EVERY PART
THAT'S SALVAGEABLE,
199
00:12:21,862 --> 00:12:24,344
INCLUDING
THE HUGE CYLINDER BLOCK.
200
00:12:24,344 --> 00:12:28,206
A COUPLE OF HOURS SOAKING IN
A HOT SODIUM-PHOSPHATE SOLUTION
201
00:12:28,206 --> 00:12:31,275
REMOVES THE GREASE
AND EXPOSES THE BARE METAL.
202
00:12:31,275 --> 00:12:35,000
ANY IMPERFECTIONS
ARE NOW MORE APPARENT.
203
00:12:35,000 --> 00:12:36,931
USING A DEPTH GAUGE,
204
00:12:36,931 --> 00:12:39,551
A TECHNICIAN MAPS OUT FLAWS,
LIKE THIS CRACK.
205
00:12:39,551 --> 00:12:43,758
IT WILL NEED TO BE FILLED,
AND HE MAKES A NOTE OF IT.
206
00:12:43,758 --> 00:12:47,034
NEXT,
A HIGH-SPEED MILLING TOOL
207
00:12:47,034 --> 00:12:49,275
CARVES OFF A THIN LAYER
OF THE STEEL,
208
00:12:49,275 --> 00:12:51,724
TAKING THE CYLINDER BLOCK'S
FINISH FROM GRIMY-GRAY
209
00:12:51,724 --> 00:12:53,551
TO BRIGHT AND SHINY.
210
00:12:53,551 --> 00:12:56,517
IT ALSO SMOOTHES AWAY
ANY UNEVENNESS
211
00:12:56,517 --> 00:12:58,655
TO CREATE A UNIFORM SURFACE
212
00:12:58,655 --> 00:13:02,379
FOR SEALING GASKETS
AROUND THE CYLINDERS LATER.
213
00:13:02,379 --> 00:13:04,275
AFTER THE INTENSIVE MACHINING,
214
00:13:04,275 --> 00:13:06,896
THE CYLINDER BLOCK
LOOKS LIKE NEW.
215
00:13:06,896 --> 00:13:09,206
IT'S BACK TO THE CRANKSHAFT NOW.
216
00:13:09,206 --> 00:13:11,965
IT, TOO, HAS UNDERGONE
AN EXTENSIVE CLEANING.
217
00:13:11,965 --> 00:13:14,344
MACHINERY GRINDS
THE OUTSIDE DIAMETER
218
00:13:14,344 --> 00:13:15,862
TO A PRECISE TOLERANCE --
219
00:13:15,862 --> 00:13:18,586
EQUIVALENT TO ONE-TWENTIETH
OF A HUMAN HAIR.
220
00:13:18,586 --> 00:13:23,103
THIS WILL ALLOW NEW,
THICKER BEARINGS TO FIT TO IT.
221
00:13:26,448 --> 00:13:29,655
THE TEAM CLAMPS WEIGHTS
TO THE MACHINE CRANKSHAFT.
222
00:13:29,655 --> 00:13:32,551
THESE WEIGHTS MIMIC
THE LOAD OF ENGINE PARTS,
223
00:13:32,551 --> 00:13:34,034
LIKE PISTONS AND RODS,
224
00:13:34,034 --> 00:13:37,310
AS THEY NOW BALANCE
THIS CRITICAL PART.
225
00:13:37,310 --> 00:13:39,068
THE CRANKSHAFT ROTATES,
226
00:13:39,068 --> 00:13:43,068
AND SENSORS DETECT VIBRATIONS
AND PINPOINT THE PROBLEM.
227
00:13:43,068 --> 00:13:46,034
AFTER MORE GRINDING
IN THESE LOCATIONS,
228
00:13:46,034 --> 00:13:50,413
THEY TEST IT AGAIN TO CONFIRM
THE CRANKSHAFT IS BALANCED.
229
00:13:50,413 --> 00:13:53,310
BACK TO THE CAMSHAFT NOW --
230
00:13:53,310 --> 00:13:55,482
A MEMBER OF THE CREW
USES A BLACK MARKER
231
00:13:55,482 --> 00:13:56,896
TO HIGHLIGHT WEAR PATTERNS.
232
00:13:56,896 --> 00:13:58,862
A GRINDER EVENS OUT THE WEAR,
233
00:13:58,862 --> 00:14:01,793
AND IT ALSO MACHINES
THE PROFILE OF EACH LOBE
234
00:14:01,793 --> 00:14:04,275
AS IT FOLLOWS
A METAL CAMSHAFT MASTER.
235
00:14:04,275 --> 00:14:09,310
THE BLACK-MARKER LINES VANISH
AS THE WEAR LINES ARE SMOOTHED,
236
00:14:09,310 --> 00:14:12,344
AND THE PROFILE OF THE CAMSHAFT
IS IMPROVED.
237
00:14:12,344 --> 00:14:16,310
A MAJOR CLEAN-UP
ALSO TRANSFORMS THE RODS
238
00:14:16,310 --> 00:14:19,034
THAT CONNECT
THE PISTON TO THE CRANKSHAFT.
239
00:14:19,034 --> 00:14:22,551
A TECHNICIAN THEN PLACES THE ROD
IN A SPECIAL HONING MACHINE
240
00:14:22,551 --> 00:14:25,379
AND ACTIVATES IT.
241
00:14:25,379 --> 00:14:30,068
FOUR ARMS WITH GRITTY ENDS
GRIND THE INSIDE OF THE ROD-HEAD
242
00:14:30,068 --> 00:14:33,758
AS THE TECHNICIAN MOVES THE ROD
BACK AND FORTH.
243
00:14:33,758 --> 00:14:36,517
THIS SIZES THE INNER DIAMETER
TO ENABLE THE ROD
244
00:14:36,517 --> 00:14:39,965
TO FIT
TO THE OTHER REVAMPED PARTS.
245
00:14:39,965 --> 00:14:43,793
ONCE ALL THE PARTS
HAVE BEEN CLEANED AND MACHINED,
246
00:14:43,793 --> 00:14:47,344
THE ENGINE IS READY
FOR REASSEMBLY.
247
00:14:47,344 --> 00:14:50,517
USING A CRANE, A TECHNICIAN
LOWERS THE CRANKSHAFT
248
00:14:50,517 --> 00:14:53,689
BACK INTO THE CYLINDER BLOCK.
249
00:14:53,689 --> 00:14:55,827
HE SECURES THE CRANKSHAFT
AT ONE END
250
00:14:55,827 --> 00:14:58,068
WITH A METAL BRACKET
CALLED A MAIN CAP.
251
00:14:58,068 --> 00:15:01,620
THERE ARE ACTUALLY
NINE MAIN CAPS IN TOTAL.
252
00:15:01,620 --> 00:15:03,620
HE GIVES THE CRANKSHAFT A SPIN
253
00:15:03,620 --> 00:15:06,034
TO CONFIRM
THAT IT ROTATES FREELY
254
00:15:06,034 --> 00:15:07,896
BEFORE INSTALLING THE REST.
255
00:15:07,896 --> 00:15:11,379
WITH A PISTON NOW ATTACHED
TO ONE END OF A CONNECTING ROD,
256
00:15:11,379 --> 00:15:13,655
HE SLIDES THE OTHER END
INTO A SLOT
257
00:15:13,655 --> 00:15:15,241
IN THE CYLINDER BLOCK.
258
00:15:15,241 --> 00:15:18,379
THIS PARTICULAR ENGINE
IS A 16-CYLINDER ONE.
259
00:15:18,379 --> 00:15:21,103
IT'S CONSIDERED MIDSIZE
FOR MINING TRUCKS.
260
00:15:21,103 --> 00:15:24,517
ONCE THE GASKETS HAVE BEEN FIXED
TO THE CYLINDER BLOCK,
261
00:15:24,517 --> 00:15:28,793
THEY BOLT
THE CYLINDER HEADS TO IT.
262
00:15:28,793 --> 00:15:32,206
THERE ARE HUNDREDS OF PARTS
IN ONE OF THESE MONSTER ENGINES,
263
00:15:32,206 --> 00:15:36,137
AND IT TAKES 700 PERSON HOURS
FOR ONE REBUILD.
264
00:15:39,379 --> 00:15:42,448
WITH THIS MINE-TRUCK ENGINE
NOW FULLY ASSEMBLED,
265
00:15:42,448 --> 00:15:46,793
THEY HOOK IT UP TO A DYNAMOMETER
TO MEASURE ENGINE PERFORMANCE.
266
00:15:46,793 --> 00:15:50,275
THEY RUN AT FULL TILT TO CONFIRM
THAT IT'S FIRING ALL CYLINDERS
267
00:15:50,275 --> 00:15:55,000
AND PERFORMING TO THE MAX.
268
00:15:55,000 --> 00:15:57,275
THIS REBUILT MINE-TRUCK ENGINE
269
00:15:57,275 --> 00:15:59,310
IS READY TO GO
BACK INTO SERVICE.
270
00:15:59,310 --> 00:16:02,862
STRONG AND HEAVILY BUILT,
THIS NINE-TON DIESEL ENGINE
271
00:16:02,862 --> 00:16:05,896
SHOULD PULL ITS OWN WEIGHT
AND THEN SOME.
272
00:16:15,862 --> 00:16:18,517
Narrator:
MUSIC, PHOTOGRAPHS, DOCUMENTS --
273
00:16:18,517 --> 00:16:21,724
WHAT USED TO TAKE UP SHELF SPACE
IN OUR HOMES OFFICES
274
00:16:21,724 --> 00:16:24,206
CAN NOW BE STORED
ON A TINY MEMORY CARD
275
00:16:24,206 --> 00:16:26,000
OR FLASH DRIVE.
276
00:16:26,000 --> 00:16:27,620
YOU CAN SAVE YOUR FILES ON IT,
277
00:16:27,620 --> 00:16:30,586
TAKE THEM OUT OF THE DEVICE
AND TRANSPORT THEM ANYWHERE,
278
00:16:30,586 --> 00:16:33,620
AS WELL AS DELETE DATA
YOU NO LONGER NEED.
279
00:16:36,068 --> 00:16:40,862
A MEMORY CARD FITS INTO A SLOT
IN YOUR DIGITAL DEVICE.
280
00:16:40,862 --> 00:16:43,551
A FLASH DRIVE PLUGS
INTO A USB PORT.
281
00:16:43,551 --> 00:16:46,103
THE KEY COMPONENT
OF BOTH FORMATS --
282
00:16:46,103 --> 00:16:47,379
A MEMORY CHIP,
283
00:16:47,379 --> 00:16:48,827
PRODUCED IN A FACTORY
284
00:16:48,827 --> 00:16:52,620
THAT'S 1,000 TIMES CLEANER
THAN A HOSPITAL OPERATING ROOM.
285
00:16:52,620 --> 00:16:57,103
IT ALL BEGINS WITH THE WAFER --
A THIN DISC OF PURE SILICON,
286
00:16:57,103 --> 00:17:01,034
A NON-METALLIC NATURAL ELEMENT
THAT CONDUCTS ELECTRICITY.
287
00:17:01,034 --> 00:17:03,379
AN AUTOMATED CONTAINER SYSTEM
288
00:17:03,379 --> 00:17:06,724
MOVES THE WAFER THROUGH
MORE THAN 800 OPERATIONS.
289
00:17:06,724 --> 00:17:07,965
AT EACH STOP,
290
00:17:07,965 --> 00:17:10,517
THE WAFER RECEIVES
ONE OF SEVERAL LAYERS
291
00:17:10,517 --> 00:17:13,758
OF NON-CONDUCTIVE MATERIALS,
SUCH AS SILICON DIOXIDE,
292
00:17:13,758 --> 00:17:16,517
AND CONDUCTIVE MATERIALS,
SUCH AS COPPER.
293
00:17:16,517 --> 00:17:20,000
THE MACHINES COAT THE LAYER
WITH LIGHT-SENSITIVE FLUID,
294
00:17:20,000 --> 00:17:23,103
THEN APPLY UV LIGHT
THROUGH A GLASS STENCIL
295
00:17:23,103 --> 00:17:26,413
OF THE COMPLEX PATTERN
OF ELECTRICAL CIRCUITRY.
296
00:17:26,413 --> 00:17:29,103
THE EXPOSED AREAS OF FLUID
CHEMICALLY REACT,
297
00:17:29,103 --> 00:17:31,620
LOCKING THE MATERIAL
DIRECTLY UNDERNEATH
298
00:17:31,620 --> 00:17:33,758
INTO THE CIRCUITRY PATTERN.
299
00:17:33,758 --> 00:17:37,586
CHEMICAL BATHS THEN REMOVE THE
SURROUNDING FLUID AND MATERIAL,
300
00:17:37,586 --> 00:17:39,896
LEAVING
ONLY THE LAYER OF CIRCUITRY,
301
00:17:39,896 --> 00:17:42,413
ELECTRICAL PATHWAYS
2,000 TIMES NARROWER
302
00:17:42,413 --> 00:17:44,517
THAN A HUMAN HAIR.
303
00:17:44,517 --> 00:17:50,034
A ROBOT TESTS THE CIRCUITRY FOR
EVERY MEMORY CHIP ON THE WAFER.
304
00:17:50,034 --> 00:17:53,724
A SINGLE WAFER,
MEASURING 12 INCHES IN DIAMETER,
305
00:17:53,724 --> 00:17:55,965
YIELDS HUNDREDS OF MEMORY CHIPS.
306
00:17:55,965 --> 00:17:59,517
THE GOAL IS TO MAKE THOSE CHIPS
AS SMALL AS POSSIBLE.
307
00:17:59,517 --> 00:18:01,655
IN THIS INDUSTRY,
308
00:18:01,655 --> 00:18:04,586
IT'S ALL ABOUT MAXIMUM MEMORY
IN MINIMAL SPACE.
309
00:18:04,586 --> 00:18:07,206
THAT'S WHY THIS OPERATION THINS
THE CHIPS
310
00:18:07,206 --> 00:18:09,896
BY GRINDING AWAY
TWO-THIRDS OF THE SILICON
311
00:18:09,896 --> 00:18:12,241
FROM THE BACKSIDE OF THE WAFER.
312
00:18:12,241 --> 00:18:15,206
AND ONE LAST STEP
BEFORE CUTTING THE WAFER
313
00:18:15,206 --> 00:18:17,275
INTO INDIVIDUAL MEMORY CHIPS --
314
00:18:17,275 --> 00:18:19,172
THIS MACHINE APPLIES TAPE
315
00:18:19,172 --> 00:18:22,034
TO HOLD
THE SEPARATED CHIPS TOGETHER.
316
00:18:25,379 --> 00:18:29,413
A COMPUTER-GUIDED SAW SLICES
THE CHIPS APART.
317
00:18:29,413 --> 00:18:32,000
CUTTING SILICON
IS LIKE CUTTING GLASS --
318
00:18:32,000 --> 00:18:34,206
IT REQUIRES
A DIAMOND-EDGE BLADE.
319
00:18:39,551 --> 00:18:42,172
IN THE NEXT STEP, A ROBOTIC ARM,
320
00:18:42,172 --> 00:18:44,655
FOLLOWING THE WAFER MAP
GENERATED EARLIER,
321
00:18:44,655 --> 00:18:46,965
PICKS UP THE CHIPS
WHICH PASS TESTING
322
00:18:46,965 --> 00:18:50,172
AND ATTACHES EACH ONE
TO A FIBERGLASS LEAD FRAME.
323
00:18:52,275 --> 00:18:54,620
THE TERM LEAD REFERS
TO THE FRAME'S PINS,
324
00:18:54,620 --> 00:18:57,724
WHICH CONNECT THE CHIP
TO THE DIGITAL DEVICE.
325
00:19:01,275 --> 00:19:04,413
ANOTHER ROBOT WIRES THE CHIP
TO THE LEAD FRAME
326
00:19:04,413 --> 00:19:07,793
WITH GOLD THREAD THAT'S ABOUT
THE WIDTH OF A HUMAN HAIR.
327
00:19:07,793 --> 00:19:12,000
GOLD IS VERY CONDUCTIVE,
SO NOW THE PATHWAY IS COMPLETE.
328
00:19:12,000 --> 00:19:14,551
ELECTRICITY WILL TRAVEL
FROM THE CHIP'S CIRCUITRY,
329
00:19:14,551 --> 00:19:18,793
THROUGH THE GOLD THREAD,
TO THE PINS, TO THE DEVICE.
330
00:19:18,793 --> 00:19:21,793
AFTER A MACHINE SEALS
THE CHIP IN PLASTIC,
331
00:19:21,793 --> 00:19:23,793
WORKERS GENTLY SNAP THEM APART
332
00:19:23,793 --> 00:19:26,586
AND INSERT THEM
IN MEMORY-CARD HOUSINGS.
333
00:19:26,586 --> 00:19:30,275
THE PLASTIC AND METAL HOUSING
IS FOR A MEMORY CARD FORMAT
334
00:19:30,275 --> 00:19:33,379
KNOWN AS COMPACT FLASH.
335
00:19:33,379 --> 00:19:35,310
A SMALL, AUTOMATED PRESS
336
00:19:35,310 --> 00:19:38,931
LOCKS THE TWO HALVES
OF THE HOUSING TOGETHER.
337
00:19:38,931 --> 00:19:43,137
THE NEXT STATION LABELS
THE FRONT OF THE HOUSING.
338
00:19:46,172 --> 00:19:49,068
EVERY SINGLE MEMORY CARD
UNDERGOES TESTING
339
00:19:49,068 --> 00:19:52,137
FOR BOTH FUNCTION AND SPEED.
340
00:19:52,137 --> 00:19:55,068
A LASER MACHINE
ETCHES PRODUCT INFORMATION
341
00:19:55,068 --> 00:19:57,896
INTO THE BACK OF THE HOUSING.
342
00:19:57,896 --> 00:20:01,275
THESE ARE ANOTHER FORMAT
CALLED SECURE DIGITAL, OR SD.
343
00:20:03,310 --> 00:20:04,896
THEY'RE ASSEMBLED AND LABELED
344
00:20:04,896 --> 00:20:08,620
JUST LIKE
THE COMPACT FLASHCARDS.
345
00:20:08,620 --> 00:20:11,655
WHEN THE FINISHED MEMORY CARDS
COME OFF THE ASSEMBLY LINE,
346
00:20:11,655 --> 00:20:15,827
WORKERS CONDUCT
A FINAL, VISUAL INSPECTION.
347
00:20:15,827 --> 00:20:18,068
ON THE FLASH DRIVE
ASSEMBLY LINE,
348
00:20:18,068 --> 00:20:20,172
MUCH THE SAME PROCESS.
349
00:20:20,172 --> 00:20:25,689
A ROBOT PUTS 20 LEAD FRAMES
ON 20 CIRCUIT BOARDS.
350
00:20:25,689 --> 00:20:28,586
THEN, A WORKER POSITIONS
20 USB CONNECTORS,
351
00:20:28,586 --> 00:20:32,034
WHICH A SOLDERING MACHINE BONDS
TO THE CIRCUIT BOARDS.
352
00:20:34,241 --> 00:20:37,655
THE FINAL STEP --
ELECTRONIC TESTING,
353
00:20:37,655 --> 00:20:39,827
TO MAKE SURE
THE USB CONNECTION IS WORKING,
354
00:20:39,827 --> 00:20:43,103
AND VIA THE CIRCUIT BOARD,
TALKING TO THE CHIP.
355
00:20:44,758 --> 00:20:50,758
THE FLASH DRIVES ARE NOW READY
TO GO INTO INDIVIDUAL HOUSINGS.
356
00:20:50,758 --> 00:20:54,448
THIS MODEL HAS
A TWO-PART PLASTIC HOUSING,
357
00:20:54,448 --> 00:20:56,482
WHICH PIVOTS IN AND OUT
OF A PLASTIC CASE,
358
00:20:56,482 --> 00:20:59,931
THAT CAN CONVENIENTLY
BE ATTACHED TO A KEY CHAIN
359
00:20:59,931 --> 00:21:02,551
OR A LANYARD
FOR EASY PORTABILITY.
360
00:21:02,551 --> 00:21:06,000
FLASH DRIVE OR MEMORY CARD,
361
00:21:06,000 --> 00:21:09,448
STORING YOUR DIGITAL EFFECTS
IS JUST A CLICK AWAY.
362
00:21:09,448 --> 00:21:12,448
--Captions by VITAC--
www.vitac.com
363
00:21:12,448 --> 00:21:15,413
CAPTIONS PAID FOR BY
DISCOVERY COMMUNICATIONS
364
00:21:22,241 --> 00:21:24,206
IF YOU HAVE ANY COMMENTS
ABOUT THE SHOW,
365
00:21:24,206 --> 00:21:26,965
OR IF YOU'D LIKE TO SUGGEST
TOPICS FOR FUTURE SHOWS,
366
00:21:26,965 --> 00:21:28,758
DROP US A LINE AT...
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