WEBVTT 1 00:00:01.000 --> 00:00:03.300 ( ♪ music playing ♪ ) 2 00:00:03.300 --> 00:00:05.300 John: Well we are so thrilled that 3 00:00:05.300 --> 00:00:07.300 you're still with us today here at Ship Shape TV. 4 00:00:07.300 --> 00:00:09.300 Where we've been showing how to put 5 00:00:09.300 --> 00:00:11.000 in a thru-hull fitting. 6 00:00:11.000 --> 00:00:13.000 And it's essential that you let that 7 00:00:13.000 --> 00:00:15.000 polyurethane adhesive setup, 8 00:00:15.000 --> 00:00:17.000 prior to cranking down 9 00:00:17.000 --> 00:00:18.000 on that flange nut. 10 00:00:18.000 --> 00:00:20.000 And rather than having idle time what 11 00:00:20.000 --> 00:00:22.000 we've done is we've changed locations 12 00:00:22.000 --> 00:00:24.000 on you. We're now down in 13 00:00:24.000 --> 00:00:28.000 Miami, Florida at the world's largest manufacturer 14 00:00:28.000 --> 00:00:30.000 of marine hardware. 15 00:00:30.000 --> 00:00:32.000 And we're at PERKO Inc. with 16 00:00:32.000 --> 00:00:33.700 my good friend, Fred Perkins. 17 00:00:33.700 --> 00:00:34.500 Hello, Fred. 18 00:00:34.500 --> 00:00:35.500 Fred: Welcome to PERKO. 19 00:00:35.500 --> 00:00:37.300 John: Thank you so much for the invitation. 20 00:00:37.300 --> 00:00:39.300 Now I understand that somebody is going to 21 00:00:39.300 --> 00:00:41.300 be giving me a factory tour. 22 00:00:41.300 --> 00:00:43.300 Who is that individual and what's 23 00:00:43.300 --> 00:00:44.000 he gonna show me. 24 00:00:44.000 --> 00:00:46.000 Fred: His name is Wolf Henning and he's 25 00:00:46.000 --> 00:00:48.000 gonna be showing you the casting process, 26 00:00:48.000 --> 00:00:50.000 the plating process and I think 27 00:00:50.000 --> 00:00:51.400 you'll find it just fascinating. 28 00:00:51.400 --> 00:00:53.100 John: Again, thank you for the invite. 29 00:00:53.100 --> 00:00:54.800 Fred: You're certainly welcome, and we're 30 00:00:54.800 --> 00:00:56.800 glad to have you here at PERKO. 31 00:00:58.000 --> 00:01:00.800 Wolf: John, what we have here is a PERKO No. 6 32 00:01:00.800 --> 00:01:02.000 thru-hull fitting. 33 00:01:02.000 --> 00:01:04.000 Marie behind us here 34 00:01:04.000 --> 00:01:06.000 is machining the head of the 35 00:01:06.000 --> 00:01:08.000 thru-hull fitting. She's machining off 36 00:01:08.000 --> 00:01:10.000 the parting line flash. 37 00:01:10.000 --> 00:01:12.000 Putting a nice smooth finish on the 38 00:01:12.000 --> 00:01:14.000 head. Then she turns it around and 39 00:01:14.000 --> 00:01:16.300 machines the end off. 40 00:01:16.500 --> 00:01:19.000 John: Here at PERKO, you guys have 41 00:01:19.000 --> 00:01:20.500 a foundry. 42 00:01:20.500 --> 00:01:22.500 And it's a special type of foundry, 43 00:01:22.500 --> 00:01:24.100 what's the real name of it? 44 00:01:24.100 --> 00:01:25.800 Wolf: It's a non-ferrous foundry. 45 00:01:25.800 --> 00:01:26.500 John: Okay. 46 00:01:26.500 --> 00:01:28.500 Wolf: Where we pour brass, 47 00:01:28.500 --> 00:01:30.200 manganese and aluminum. 48 00:01:30.200 --> 00:01:31.300 John: Very good. 49 00:01:31.300 --> 00:01:33.300 Now this is actually an alloy, 50 00:01:33.300 --> 00:01:35.300 and let's talk about the 51 00:01:35.300 --> 00:01:36.700 ingot that you're getting. 52 00:01:36.700 --> 00:01:38.700 Naturally, it'd be bronze ingots. 53 00:01:38.700 --> 00:01:40.700 And those need to get melted down. 54 00:01:40.700 --> 00:01:42.700 But what do you add to the bronze 55 00:01:42.700 --> 00:01:44.700 in order to give you something that's gonna 56 00:01:44.700 --> 00:01:46.700 hold up in saltwater and freshwater. 57 00:01:46.700 --> 00:01:48.800 Wolf: At the time that we melt the ingot, 58 00:01:48.800 --> 00:01:50.800 we add pure zinc to it. 59 00:01:50.800 --> 00:01:52.800 Which helps us get rid of some of the 60 00:01:52.800 --> 00:01:54.800 impurities in the metal that float 61 00:01:54.800 --> 00:01:56.800 to the surface and get stripped off. 62 00:01:56.800 --> 00:01:58.600 John: How do you actually make the part? 63 00:01:58.600 --> 00:02:00.000 Where does it begin? 64 00:02:00.000 --> 00:02:02.000 Wolf: We start out by making the core 65 00:02:02.000 --> 00:02:04.000 which forms the inside of the part. 66 00:02:04.000 --> 00:02:06.000 The core is made on a core machine 67 00:02:06.000 --> 00:02:07.800 in a core box. 68 00:02:07.800 --> 00:02:09.500 The core box is heated up to about 69 00:02:09.500 --> 00:02:11.000 600 degrees. 70 00:02:11.000 --> 00:02:13.300 The sand is blown up inside 71 00:02:13.300 --> 00:02:15.300 into core box. Where the 72 00:02:15.300 --> 00:02:17.500 600 degrees "pures" the sand. 73 00:02:17.500 --> 00:02:19.200 John: What kind of sand are you using? 74 00:02:19.200 --> 00:02:21.400 Wolf: It's a silica sand, with a binder in it. 75 00:02:21.400 --> 00:02:22.400 John: Okay. 76 00:02:22.400 --> 00:02:24.600 Wolf: And the sand is cured 77 00:02:24.600 --> 00:02:26.600 under the high temperature. 78 00:02:26.600 --> 00:02:28.600 The core boxes open up and the cores 79 00:02:28.600 --> 00:02:31.000 are removed. The cores cool down 80 00:02:31.000 --> 00:02:33.000 and then they're used in the 81 00:02:33.000 --> 00:02:35.000 molds to form the inside of the part. 82 00:02:35.000 --> 00:02:37.000 John: Okay so you need to have a mold when 83 00:02:37.000 --> 00:02:38.600 you're making castings. 84 00:02:38.600 --> 00:02:40.900 But you also need to have some 85 00:02:40.900 --> 00:02:42.900 type of a pattern? 86 00:02:42.900 --> 00:02:43.900 Wolf: Yes. 87 00:02:43.900 --> 00:02:45.400 John: What's that made out of? 88 00:02:45.400 --> 00:02:47.400 Wolf: The patterns are made out of aluminum. 89 00:02:47.400 --> 00:02:51.300 They're using multiple impressions on the pattern. 90 00:02:51.300 --> 00:02:53.300 In this particular case there are 91 00:02:53.300 --> 00:02:55.300 six impressions on the pattern. 92 00:02:55.300 --> 00:02:57.300 Half of the part is on the top of the 93 00:02:57.300 --> 00:02:59.800 pattern and the other half is on the bottom of the pattern. 94 00:02:59.800 --> 00:03:02.000 John: So the same pattern is making 95 00:03:02.000 --> 00:03:03.800 both sides to the mold. 96 00:03:03.800 --> 00:03:05.900 There's two parts to a mold, 97 00:03:05.900 --> 00:03:07.600 that have to come together. 98 00:03:07.600 --> 00:03:08.300 Wolf: Correct. 99 00:03:08.300 --> 00:03:10.800 John: What type of sand do you use in the foundry? 100 00:03:10.800 --> 00:03:12.900 Wolf: We use an olivine sand 101 00:03:12.900 --> 00:03:14.900 with a grey binder in it. 102 00:03:14.900 --> 00:03:17.700 The sand is about 110 grit. 103 00:03:17.700 --> 00:03:19.700 John: So the sand gets compacted, 104 00:03:19.700 --> 00:03:21.700 and what do you do? Do you place the core 105 00:03:21.700 --> 00:03:24.000 into the mold at this point? 106 00:03:24.000 --> 00:03:26.000 Wolf: Well the sand gets compacted 107 00:03:26.000 --> 00:03:28.200 into two halves and the mold separates. 108 00:03:28.200 --> 00:03:30.200 The pattern doesn't move from 109 00:03:30.200 --> 00:03:32.300 between the two halves. And then the core 110 00:03:32.300 --> 00:03:34.300 are set into the mold. 111 00:03:34.300 --> 00:03:37.100 The mold is then put back together again. 112 00:03:37.100 --> 00:03:38.900 The two halves are put back together and they're 113 00:03:38.900 --> 00:03:41.500 shuttled down the conveyor to the pouring station. 114 00:03:41.500 --> 00:03:43.500 John: Let's talk about the pouring station 115 00:03:43.500 --> 00:03:45.700 You've got all of this metal 116 00:03:45.700 --> 00:03:47.700 heated up in a melting pot - 117 00:03:47.700 --> 00:03:49.600 it's actually called a crucible right? 118 00:03:49.600 --> 00:03:50.400 Wolf: Correct. 119 00:03:50.400 --> 00:03:52.400 John: How do you get this molten 120 00:03:52.600 --> 00:03:55.500 metal, from the melting pot 121 00:03:55.500 --> 00:03:57.500 from where it's heated up. 122 00:03:57.500 --> 00:03:59.500 Over to the pour station where 123 00:03:59.500 --> 00:04:01.200 you're pouring it into the mold. 124 00:04:01.200 --> 00:04:03.200 Wolf: We use an induction furnace. 125 00:04:03.200 --> 00:04:05.700 The crucible is about 300 pounds, 126 00:04:05.700 --> 00:04:08.400 heated up to about 2100 degrees. 127 00:04:08.400 --> 00:04:10.400 From there it's conveyed to the 128 00:04:10.400 --> 00:04:12.400 pouring station by an air hoist. 129 00:04:13.200 --> 00:04:16.900 John: Now your pouring multiple molds at this point. 130 00:04:17.500 --> 00:04:19.500 And how long does it take to 131 00:04:19.500 --> 00:04:21.700 cool down to where you actually 132 00:04:21.700 --> 00:04:24.500 have some resemblance of a part? 133 00:04:24.500 --> 00:04:26.500 Wolf: It takes about 45 minutes, 134 00:04:26.500 --> 00:04:28.500 before the mold hits their shakeout 135 00:04:28.500 --> 00:04:30.200 where we can take the parts out. 136 00:04:30.200 --> 00:04:32.000 At that time they're still very hot. 137 00:04:32.000 --> 00:04:34.200 John: How do you break 138 00:04:34.200 --> 00:04:36.200 the thru-hull from... 139 00:04:36.200 --> 00:04:38.200 ...what do you call it that's holding 140 00:04:38.200 --> 00:04:39.700 all the pieces together? 141 00:04:39.700 --> 00:04:42.600 Wolf: The parts are held on a runner and gate system. 142 00:04:42.600 --> 00:04:43.200 John: Okay. 143 00:04:43.200 --> 00:04:45.200 Wolf: And the thru-hull system 144 00:04:45.200 --> 00:04:47.200 the gates are very thin and we could 145 00:04:47.200 --> 00:04:48.800 break them off by hand. 146 00:04:48.800 --> 00:04:50.500 John: Now with a mallet you're kind of 147 00:04:50.500 --> 00:04:51.800 breaking these things off. 148 00:04:51.800 --> 00:04:52.400 Wolf: Right. 149 00:04:52.400 --> 00:04:54.400 John: From that point, it comes over here 150 00:04:54.400 --> 00:04:55.600 to the machining area. 151 00:04:55.600 --> 00:04:56.200 Wolf: Correct. 152 00:04:56.200 --> 00:04:57.700 John: And you mill the face 153 00:04:57.700 --> 00:04:59.100 on the thru-hull fitting, 154 00:04:59.100 --> 00:05:00.400 you mill the backside. 155 00:05:00.400 --> 00:05:01.900 Where does the threads actually get 156 00:05:01.900 --> 00:05:03.100 cut into the thru-hull? 157 00:05:03.100 --> 00:05:04.800 Wolf: The threads are cut into another 158 00:05:04.800 --> 00:05:07.100 on another machining center. 159 00:05:07.100 --> 00:05:09.100 Where they first take a skin cut off 160 00:05:09.100 --> 00:05:10.600 to remove the skin. 161 00:05:10.600 --> 00:05:12.200 And then there's the threading tool which 162 00:05:12.200 --> 00:05:14.700 cuts the thread into their offset. 163 00:05:14.700 --> 00:05:16.800 John: Hey right now we need to take another timeout 164 00:05:16.800 --> 00:05:18.800 but keep it right here because when we come back, 165 00:05:18.800 --> 00:05:21.200 we will go through the plating process. 166 00:05:21.200 --> 00:05:22.900 And this is very fascinating! 167 00:05:22.900 --> 00:05:24.900 We'll cover it, right after this.