Here's the converted content:

WEBVTTKind: captionsLanguage: en- We've all heard the saying,

The webvtt kind and language are specified in the file content.

We've all heard the saying,

It is a quote that has been widely shared.

WEBVTTKind: captionsLanguage: en- We've all heard the saying,"If it ain't broke, don't fix it".Apparently there's aGerman company out therethat doesn't speak English,(gasping)called Porsche.They recently developed away to 3D print a piston,changing a design that'sover 300 years old.That's older than toilet paper.Just think about that for a second.Pistons have been around longerthan we've been wipingour butt with paper.So what I wanna knowis how is Porsche's piston of the futuredifferent from the ones inside your car.And maybe more importantly,why fix what ain't broke?Let's go(upbeat music)- Thanks to Off the Recordfor sponsoring this episode.(crashing)Well, well, well,did someone have a little bit too much funthis holiday weekend?Is this your only form of transportationbecause you were getting alittle too fast and furious?And now you're stuck with a ticketthat's gonna break the bank?Well, unstuck yourself,and avoid that insuranceincrease by using Off the Record.They've got a fast andeasy technology centric wayto fight your ticket and save you money.- Registernow to use code Donutfor 10% off your first ticketat offtherecord.com/donut.- Check this out.- To understand why these newpistons are such a big deal,we need to take a closer lookat what happens toordinary pistons in carslike yours and mine and how they are made.The piston is the firstcomponent in a chain of partsthat converts the directional forceof that combustion energyinto a mechanical rotational force.And a single piston will be exposedto billions of thesecombustions during its life.So how powerful is that releaseof energy from a combustion?Well, at 6000 RPM and at full throttle,each piston is exposedto nearly 10 tons offorce every 0.02 seconds.A lot of energy released fromcombustion is heat energyand the pistons are travelingat up to 27 meters per second,creating even more heat from friction.They reach temperaturesup to 310 degrees C.And to survive such extreme punishment,a piston has to be madefrom something really tough,and typically that meansa really high quality aluminum alloy.So are Porsche's revolutionary new pistonsmade from some space age material instead?Or maybe some sort of carbonceramic or carbon fiber?NASA, they actually have a patenton a carbon ceramic piston design,but it's estimated they costaround $4,000 to manufacturer,which wouldn't be practicalfor us normal boys and girlslike you and I.So Porsche's new pistons,they're not made out ofsome Sci-Fi super pricing materials.Like nearly every automotive piston todaythey're made from an aluminum alloy.But how they are madeis something very new.Now, there are a couple ofways we can make pistons.We can cast them, we can forgethem or we can machine them.A casting involves heatinga metal until it's liquidand pouring it into a mold,it's kind of like jello.Or if you had a CreepyCrawlers machine from the 90's.I love making Creepy Crawlies.Now, these pistons can have complex shapeswith Val pockets, ringgrooves and cooling gallerieswithout a lot of expensive finishing.And casting, it's quick and inexpensive,and that's why your streetcar probably has cast pistons.Now, forging is slower and more expensivebut creates stronger parts.Forging takes a heated billet of metaland presses it into the desired shape.Because you're not meltingthe billet into a liquid,the metal maintains the grainfrom which the billet was formed.Much like the grain in a piece of wood,that internal layering adds toughness.And because of this forgedpistons are more ductile,which means they deform insteadof breaking under stress.A good example of this isgetting a switch off a treethat's nice and new,it's really supple and it moves,so when it whacks your legit hurts like a mother (beep).Now, maintaining ductilitycomes at a price.Forge pistons expand and contractmore under temperature changes.That means forge pistons canbe loose in the cylinderswhen the engine is cold.This produces what's called piston slapas they rattle around.Until the pistons get warm backup enough to seal properly,they simply can't contain the combustioninside the cylinders.So if Porsche isn't usingany of these more traditionaltechniques in making a piston,how are they doing it?Well, they went with a techniquethat uses metal dust and freaking lasers.The process is called Laser Metal Fusion.A type of 3D printingbased on precision welding.Porsche's process uses aproprietary aluminum alloycalled M174+.Plus means it's freaking better.And that proprietary aluminum alloy,it comes as a powderwhich is distributed in a thin layerinside a highly specialized 3D printerfrom another German company,frigging Germans man.And a 12-hour process, 1200 layers,each less than one 10thof a millimeter thickare micro welded by robotic lasers.And since the metal particlesare bonded at such a fine scale,the powder has to be incredibly pure,precisely mixed and perfectly weldedto avoid imperfections or weakness.The piston's final step is Quality Controlat yet another Germancompany called Zeiss,known for their precision optical systems.And at Zeiss, each piston is examinedwith an electron microscope in CT scansto make sure they're free of any invisibleor internal defects.This whole process involvesa lot of attention to detail.And it's not just becausethese are German engineers.Oh, no, ordinary pistonsare subjected to pressuresat over 2000 PSI.Temperatures that can melt pure leadand accelerations from 0-60and back to zero in 3.4thousands of the second.You wanna know how fast that is?It's this fast.Okay, but hang on,if ordinary cast or forgedpistons can withstand that,why go to all the trouble ofdoing something different?Is it just because the technologyis out there and exist?Well, the reason why Porsche's pistonuses this new manufacturing techniqueis because they can't beproduced by forging or casting.Their unique design is whatmakes them truly futuristic.Porsche's pistons are designedusing topological optimization.That's when a 3D schematic of a partis entered into a computer,which then simulateswhere the load will occuron that particular part.The computer modifies the designto remove any unneeded material.And the result is calleda bionic architecture.Based on the idea that nature,it doesn't waste any resourceswhen it produces a structure.If you wanna learn more about this,you should check out our videoon AI Designing Parts for Car right here,click right there.Porsche topological optimizationled to a piston designthat is 10% lighter.Now that might not seem like muchwhen it comes to 300 grand piston,but the rapid directionchanges they experienceinside an engine means thata piston can be exposedto 200 G's of accelerationand deceleration force.That gives a 300 grand pistonan effective mass at around 60 kilograms.And under normal conditions,that's enough to warpthe solid steel risk pinthat connects the pistonto the connecting rod.So, Porsche's 10% weightloss plan is a big deal.And part of the results arevisible on the underside,which contains less materialthan a typical piston.And it kind of lookslike the inside of a ear.Check out my ear, okay, that's my ear,Ear, piston.Ear, piston.They're like pretty much the same thing.Now, you couldn't machine those shapesinto a forge or cast piston,but it would take a lot oftime and a lot of precision.And even more weight is savedwithin the piston itself,some of which is built intoa honeycomb like structure.Topological optimizationreveals that excess material exists herein an ordinary piston,but fully enclosedhollow spaces like theseare impossible to create withforging or casting alone.3D printing also allows fora better cooling galleryto be placed in the piston.Topological optimization shows exactlywhere oil should besquirted into the pistonto cool the areas under greatest load,producing an overall dropin operating temperatureof 20 degrees C.Cooling galleries like this oneare difficult to create with castingand impossible to create with forging.You wanna know the other wayyou can have some cooling power?Joining the Donut Underground- You need Alexis first aid kit?- Wow, I bet thosebandaids are expired?(laughing)- Listen, I don't thinkbandaids expire, right?That's not a thing that's expirable.- So is this stripped downbionic structure reliable?Well, there's some reasonsto worry that it might not be.The 3D printing processdoesn't create the grainthat gives a forged piston it's strength.So Porsche really needed to knowhow strong their new pistons are,so they use the 700 horsepowertwin-turbo 3.8-liter enginefrom their 911 GT2 RS to find out.On a test bench, they ran a GT2 RS motorwith these new pistons for 200 hours.They simulated theconditions of a 24-hour race,including refueling stops andmultiple poles from a stopto the 7300 RPM red line.They then ran the engineunder varying accelerationand deceleration loads for 25 hours.They even left the enginerunning at full loadfor 135 hours.Then they removed the pistonsand had Zeiss reexamined them,guess what?They didn't find any defects.So what does a 10% weight savingsand 20 degrees extra coolingmean for performance?Well, lighter pistons meanthat the engines red linecould be safely increased by 300 RPM.(indistinct) pistons meetuncontrolled detonationin the cylinders is also less likely.And then a GT2 RS motor,that extra RPM andmodified ignition timingcombined for an extra 30 peak horsepower.But Porsche isn't stopping yet.They say they've been conservative so farwith producing material on the pistonsand making changes to the engine.They even ran somesimulations that suggestthat they could see 20%more weight reductionin future versions.More weight reduction meansthat other engine components,like the dampeners thatcontrol piston vibrations,those can also be made lighter.And you get lighter parts,you can rev up quicker and you can make-- Are you serious dude?Nah, come on it's (indistinct) episode.- Go ahead.- More power baby.- Yeah.- So, when can you buy a production carwith bionic 3D printed pistons?Porsche says that they'reless than a decade away.10 years, what the (beep),I gotta wait 10 years.Porsche says that they'reless than a decade away.But these experiments aren't just changingthe future of GT2 buyers,engineers at MAHLE whohelped develop porches pistonsay they'll soon be ableto produce the pistonsand other components in small numbers,quickly and on demand.Because they won't need to makeor stock expensive forgingequipment or molds.Not only can they reproduceparts for old carsbut they can improve performance partsfor nearly any car by usingtopological optimization.Thank you guys so much forwatching this episode of B2B.We're here every Tuesday,click that like button,click that subscribe button.Follow us on Instagram @Donutmedia,follow me @JeremiahBurton.Till next week, bye for now.