Edexcel Resistant Materials

1. Edexcel Resistant Materials What you must know??? This presentation is being updated all the time so make sure you come back and check regularly to see the updates.

2. Unit 2 Knowledge and Understanding of Resistant Materials • Technology 24 • Topic 1 Materials and components 25 • Topic 1.1 Woods 25 • Topic 1.2 Metals 26 • Topic 1.3 Polymers 27 • Topic 1.4 Composites 27 • Topic 1.5 Modern and smart materials 28 • Topic 2 Tools and equipment 28 • Topic 2.1 Marking out and measuring 28 • Topic 2.2 Wasting 29 • Topic 3 Industrial and commercial processes 29 • Topic 3.1 Scale of production 29 • Topic 3.2 Materials processing and forming 30 • Topic 3.3 Joining methods 30 • Topic 3.4 Adhesives 31 • Topic 3.5 Heat treatment 31 • Topic 3.6 Finishing techniques 32 • Topic 3.7 Manufacturing processes for batch production 32 • Topic 3.8 Health and safety 32

3. Topic 4 Analysing products 33 • Topic 4.1 Specification criteria 33 • Topic 4.2 Materials and components 33 • Topic 4.3 Manufacturing processes 34 • Topic 5 Designing products 34 • Topic 5.1 Specification criteria 34 • Topic 5.2 Designing skills 35 • Topic 5.3 Application of knowledge and understanding 35 • Topic 6 Technology 35 • Topic 6.1 Information and communication technology (ICT) 35 • Topic 6.2 Digital media and new technology 36 • Topic 6.3 Computer-aided design/computer-aided manufacturing • (CAD/CAM) technology 36 • Topic 7: Sustainability 36 • Topic 7.1 Minimising waste production 36 • Topic 7.2 Renewable sources of energy 37 • Topic 7.3 Climate change 37 • Topic 8 Ethical design and manufacture 37 • Topic 8.1 Moral, social and cultural issues

4. Natural Woods • Uses • High quality furniture • Beams used in buildings • Veneers • Description • A very strong, light-brown wood • Open grained • Very hard, but quite easy to work with Oak Mahogany • Description • Reddish-brown in colour • Easy to work with • Uses • Indoor furniture • Shop fittings • Bars • Veneers Beech • Description • A straight- grained hardwood with a fine texture • Light in colour • Very hard but easy to work with • Can be steam bent • Uses • Furniture • Toys • Tool handles • Description • Open grained • Easy to work with • Pale cream colour, often stained black • Can be laminated (i.e. sliced into veneers which are glued together) • Uses • Tool handles • Sports equipment • Furniture • Ladders • Veneers Ash

5. Natural Woods Pine • Description • Pale-yellow coloured with dark lines and a fine, even texture. • Medium in weight • Stiff and stable • Inexpensive • Uses • Readily available for DIY work • Mainly used for constructional work and simple joinery • Furniture

6. Medium density fibreboard (MDF) Hardboard Man-Made Woods • Description • Has a smooth, even surface • Easily machined and painted • Available in water and fire-resistant form • Often veneered or painted to improve its appearance • Uses • Furniture and interior panelling Chipboard • Description • Made from chips of wood glued together with urea formaldehyde (glue) • Usually veneered with an attractive hardwood or covered in plastic laminate • Uses • Kitchen and bedroom furniture • Shelving and general DIY Work Plywood • Description • A very strong board, constructed of layers of veneer or piles, which are glued together with the grains at 90° to each other • Interior and exterior grades available. • Uses • Furniture making • Boat building and exterior work • Description • A very cheap particle board • Can have a laminated plastic surface • Uses • Kitchen unit and furniture back panels

7. Plastics Acrylic • Properties: • Hard wearing • Will not shatter • Can be coloured • Bathtubs, School Projects, Display signs Polypropylene • Properties: • High Impact strength • Softens at 150°C • Can be Flexed many times without breaking • School chairs, Crates High Impact Polystyrene (HIPS) • Properties: • Light but strong • Widely available in sheets • Used for casings of electronic products

8. Plastics Polythene (LDPE) • Properties: • Weaker and softer than HPDE. • Lightweight • Carrier Bags + Squeezy Bottles Polythene (HDPE) • Properties: • Stiff strong plastic • Used for pipes and bowls • Buckets Urea formaldehyde • Properties: • Colourless plastic • Can be coloured • Door and cupboard handles, Electrical fittings

9. Metals Aluminium • Properties: • Light Weight • Light grey in colour • Can be polished to a mirror like appearance • Rust resistant Mild Steel • Properties: • Heavy • Dark grey in colour • Rusts very quickly if exposed Stainless Steel • Properties: • Heavy • Shiny appearance • Very resistant to wear / rust.

10. Metals Cast Iron • Properties: • Re melted pig iron with some quantities of other metals • Strong in compression. • Brittle Copper • Properties: • Reddish brown metal. • Soft • Excellent conductor of heat and electricity Brass • Properties: • Yellow metal • Hard • Alloy

11. Composites – Carbon Fibre • Carbon Fibre is sometimes referred to as Carbon Fibre Reinforced Plastic is similar to fibre glass. Carbon fibre is woven into a textile material and resin such as epoxy resin is applied and allowed to cure. The resulting material that is very strong as it has the best strength to weight ration of all construction materials. It is an improvement on glass fibre reinforced plastic, although much more expensive. •   Carbon Fibre Reinforced Polymers tend to be used in the manufacture of expensive sports cars, where strong and light materials are required. Expensive, competition bicycles and motorbikes tend to have CFRP frames, forks, handlebars to keep weight to a minimum and yet retain great strength. The aerospace industry has embraced the use of CFRP in the manufacture of planes. Eurofighter has a large proportion of its airframe manufactured from Carbon Fibre Reinforced Plastic.

12. FIBREGLASS / GLASS REINFORCED PLASTIC (GRP) • Fibreglass is an excellent example of a relatively modern composite material. In industry it is often referred to as Glass Reinforced Plastic (GRP).GRP is composed of strands of glass. Each individual glass fibre is very fine with a small diameter, and they are woven to form a flexible fabric. The fabric is normally placed in a mould, for instance a mould for a canoe and polyester resin is added, followed by a catalyst. The process is repeated so that there are many layers of fibre glass and resin and allowed to dry/cure. The resulting material is strong and light. Glass Reinforced Plastic can be sanded for a smooth finish and painted. • Glass reinforced plastic is lightweight and has good thermal insulation properties. It has a high strength to weight ratio, making it useful for the production of products such as water tanks, surfboards, canoes, small boat hulls and similar products.

13. Material Properties Strength The ability of a material to stand up to forces being applied without it bending, breaking, shattering or deforming in any way.Our technology technician (Ed) demonstrates the ‘strength’ of a material by performing a hand stand on a strong piece of timber (wood). It does not bend even under his weight. He has eaten pies and drunk a large amount of beer for twenty years and yet the strong material does not bend, flex or deform (change shape) in any way. Elasticity The ability of a material to absorb force and flex in different directions, returning to its original position.Our technology technician demonstrates the ‘elasticity’ of a material by springing up and down on a piece of steel rod. Do not try this at home as an accident may result. Ed our technician is an expert at demonstrating this property as it is his hobby.

14. Material Properties 2 Ductility The ability of a material to change shape (deform) usually by stretching along its length.Our technician stretches the lead above his head. As it stretches if deforms (changes shape).Ed thinks he is a strong man, little does he realise that lead is a very soft metal and stretches very easily. He performs these tricks in local pubs in an attempt to pass himself off as a ‘hard man’. Malleability The ability of a material to be reshaped in all directions without crackingOur technology technician demonstrates the ‘malleability’ of a material by heating a piece of mild steel until it is red hot. He then beats it with a large forging hammer to reshape it. Because of the high temperature it reaches while heating the steel becomes malleable, it can be reshaped permanently.Ed often heats up steel, because he likes the colour and it matches his complexion after he has run up the stairs.

15. Material Properties 3 Hardness The ability of a material to resist scratching, wear and tear and indentation.Our technology technician, dressed in a kilt, slides along the floor to see if it will scratch. It will be considered to hard wearing if it resists scratching.Ed has been known to fall over. Not a sight for sore eyes. Toughness A characteristic of a material that does not break or shatter when receiving a blow or under a sudden shock.Our technology technician demonstrates the ‘toughness’ of a material by hitting a piece or material to see if it will break or shatter. Ed has been known to test authentic Chinese Ming Dynasty pottery with the same technique. This is why he is often arrested in Museums and has been banned from the local Antique dealers.

16. Modern & Smart Materials 1 Shape memory alloys (SMA) SMA wire is sometimes called ‘Nitinol’, as it is a composed of nickel and titanium. On first site this special wire looks like ordinary wire and even has many of the same properties. It can be folded to form complex shapes quite easily and it conducts electricity. However, it is very expensive when compared to ordinary steel or even copper wire. However, it has properties that make it very special: The wire has a memory - for example, if it is folded to form a shape and then heated above 90 degrees (centigrade) it returns to its original shape.

17. Modern & Smart Materials 2 Photochromic paint Photochromic paint darkens, as the light level increases. Some photochromic paints change colour. In fact, it is UV light (Sun Light) that causes the darkening of the ink, which means the ink works best in natural light. This special paint has two main applications; sunglasses and spectacles. However, it is also used in novelty items such as embroidery thread and toys, where colour change takes place according to light level. Nail lacquer / varnish is also available with photochromic technology. Changing Lens Glasses / Transition Lenses The tint of a photochromic lens changes according to the intensity of natural light (UV light). Inside a building, the lenses remain clear but they darken when outside in sunlight. Spectacles with this type of lens are comfortable to wear, in all conditions. However, they are more expensive than spectacles with normal, clear lenses. Novelty Teddy BearThe teddy bear seen opposite is an example of a novelty toy. The sunglasses and ribbon change colour when exposed to natural light (sun light). The ribbon on the bowler hat, also changes colour.

18. Modern & Smart Materials 3 d30 d3o™ Intelligent Shock Absorption™ is a patented, shock absorbing material, engineered with Intelligent Molecules. d3o™ is rate-sensitive meaning that when moved slowly, the molecules flow freely making it soft and flexible. At high speeds however like in an impact the molecules lock together making the material an excellent shock absorber. The whole process is repeatable, occurs instantly and returns to its original state as soon as the impact is over.d3o™ is also extremely low profile and integrates seamlessly into garments, so neither style or function has to be compromised. These qualities make it perfect for any application where you need total freedom of movement and excellent shock absorption.

19. Marking Out and Measuring 1 Centre Punch Centre punches are used to make an indent in the surface where holes are to be drilled in metal. They provide a starting point for the drill and stop it skidding over the surface. Micrometer Although the micrometer provides a very accurate measurement, it can be difficult to learn how to read it. • Topic 2.1 Marking out and measuring • What students need to learn • Recognition, selection, use and advantages/disadvantages of the • following tools and equipment when marking out and measuring during • the manufacture of products: • squares • gauges Templates A template is used when a number of identical shapes or patterns need to be marked out. You can make a template from any thin material, such as plywood or aluminium, that is easy to draw around. Rules Scribers A scriber is used to scratch the surface of metal and plastic lightly.

20. Marking Out and Measuring 2 • Squares • There are a number of squares: • Try square • Engineer’s square • Mitre square • Take great care when using any form of square for marking out or • checking, and ensure that it is being held firmly and tightly against the • surfaces or edges of the material. • Topic 2.1 Marking out and measuring • What students need to learn • Recognition, selection, use and advantages/disadvantages of the • following tools and equipment when marking out and measuring during • the manufacture of products: • squares • gauges

21. Marking Out and Measuring 3 • Gauges • There are three basic types of gauge: • Marking gauge - is used for marking lines parallel to the face edge and side on wood • Mortise gauge - It is used for marking two parallel lines where a mortise and tenon joint is to be cut. It has two pins; one pin is fixed and the other is adjustable. • Cutting gauge - is used for cutting across the grain. It is used in the same way as a marking gauge • Topic 2.1 Marking out and measuring • What students need to learn • Recognition, selection, use and advantages/disadvantages of the • following tools and equipment when marking out and measuring during • the manufacture of products: • squares • gauges

22. Wasting Tools - Saws Saws Saws are used to cut material that is not needed away from material which is. Saw blades have alternate teeth bent out or ‘set’ in opposite directions. When using a saw, you should always cut to the waste side of the marked line so that you leave a small amount for finishing by either sanding or filing.

23. Wasting Tools - Planes Planes Planes are used to smooth wood flat and to reduce to size. A jack smoothing plane, which is used for finishing and planing end grain because it is easier to handle than a jack plane. A block plane is the smallest plane and is generally used for removing sharp edges and for putting a small bevel along an edge. chisels files drills abrading tools.

24. Wasting Tools - Chisels Wood Chisels Four basic wood chisels are used in the school workshop: • the firmer chisel is a general-purpose chisel, which has a square • edge • a bevel-edge chisel has a bevelled blade that allows it to get into corners and is especially useful for cutting dovetails • mortise chisels have much deeper blades and are used with a mallet for cutting mortise joints • gouges have curved blades and are used for carving. Metal Chisels Cold chisels can be used to cut sheet metal, either by shearing across it or by chopping down on it vertically. They have a hardened and tempered cutting edge while the other end is left soft to absorb the impact from the hammer blows. Different profiles are available, allowing access to corners or for producing grooves in the workpiece files drills abrading tools.

25. Wasting Tools – Abrading Tools Abrading tools Abrading tools remove very small particles of waste, such as those produced by filing. Abrading tools include rasps, which are used on wood, and surforms. Surformshave replaceable blades. They are formed and operate a bit like a cheese grater. Abrasive papers are also available for wood, metal and plastics. Glasspaper, sometimes called sandpaper, is used on wood. Emery cloth is used on metals and plastics. Any form of abrasive paper is best used wrapped around a cork block. This ensures that an even pressure is applied over the work. files drills abrading tools.

26. Wasting Tools – Files • Files • Two basic filing processes are used in the workshop: • Cross-filing - Cross-filing removes waste rapidly. You should use the whole length of the file with a downwards force. The file only cuts forwards. It should be lifted off at the end of the stroke and not dragged back across the workpiece. • Draw-filing -Draw-filing removes marks in the work left as a result of cross-filing. This method gives a much better surface finish, and a smoother file should always be used for draw-filing. • General work is carried out with a flat file. One of the long edges has teeth; the other is plain and is known as a safe edge. The safe edge prevents cutting into the face of a square corner. Files with different profiles are available for a range of applications. There are also other, more specialist forms of file drills abrading tools.

27. Wasting Tools – Drills Drills Twist drills, the most common type of drill used in school workshops, can create holes in most materials. There are many other forms of drill, each with its own specific use and application. The most common types used in school workshops are shown below.

28. Production Methods One off production - This is when only one product is made at a particular time. This one off product could be a prototype a one off object or a hand made object. Prototypes are made to see if a product works before it goes into large scale production. One off production takes a long time and often means it is expensive. A classic product could be a mobile phone prototype, a one off specialist product, handmade items, etc. Batch production - This is when a series of products which are all identical are made jointly in either large or small numbers. Once these have products have been made once more of the same products may be made using the same equipment. This equipment includes tools, moulds, machinery and labour. A classic product could be a chair, newspapers, books, electrical products, etc. Mass production - Mass production involves the product going through many stages of a production line. There are workers and machines at certain stages along the line that are responsible for making certain parts of the product. This means the product is often made over days or even weeks depending how complicated it is. This product is often quite reasonably priced due to the large scale production techniques used. However if a problem occurs it will stop the whole line of production. A classic product could be a car. Continuous production - This is where a product is continuously produced over a period of hours, days, weeks or even years. This kind of production means the product will often be quite reasonably priced. A classic product could be screws, bricks, food products, etc Just in time production - Just in time production means just that. This involves the arrival of parts at just the exact time that they are required in the factory. This means that less storage space is needed at the factory, so saving space at the factory. If the flow of parts is stopped or is late the line will stop and this production technique could then become very costly. • Topic 3.1 Scale of production • What students need to learn • Characteristics, application and advantages/disadvantages of the • following scales of production in the manufacture of products: • one-off • batch • mass.

29. Materials Processing & Forming – Sand Casting • There are six steps in this process: • Place a pattern in sand to create a mold. • Incorporate the pattern and sand in a gating system. • Remove the pattern. • Fill the mold cavity with molten metal. • Allow the metal to cool. • Break away the sand mold and remove the casting.

30. Materials Processing & Forming – Drilling

31. Materials Processing & Forming – Turning

32. Materials Processing & Forming – Blow Moulding Blow moulding a shape is a common industrial process. The example shown below is of the production of a plastic bottle. The plastics normally used in this process are; polythene, PVC and polypropylene. The process is similar to injection moulding and extrusion: 1. The plastic is fed in granular form into a 'hopper' that stores it. 2. A large thread is turned by a motor which feeds the granules through a heated section. 3. In this heated section the granules melt and become a liquid and the liquid is fed into a mould. 4. Air is forced into the mould which forces the plastic to the sides, giving the shape of the bottle. 5.  The mould is then cooled and is removed.

33. Materials Processing & Forming – Injection Moulding Materials such as polystyrene, nylon, polypropylene and polythene can be used in a process called injection moulding. These are thermoplastics - this means when they are heated and then pressured in a mould they can be formed into different shapes. The DVD Storage unit seen opposite has been made in one piece using this processAn animation of an injection moulding machine is shown below. The product being produced is the DVD / CD storage unit seen opposite.

34. Materials Processing & Forming – Vacuum Forming Vacuum forming is a technique that is used to shape a variety of plastics. In school it is used to form/shape thin plastic, usually plastics such as; polythene and perspex. Vacuum forming is used when an unusual shape like a ‘dish’ or a box-like shape is needed. Below you can see the stages involved in vacuum forming. Below is an example of a vacuum formed toy. The simple 'lorry' mould has been placed in a vacuum former and a compressed polystyrene sheet has been placed above it. The polystyrene has been heated and then vacuum formed to the shape of the mould. Many everyday items have been vacuum formed in this way. Look around your home - list some examples. as a guide - some food products are packaged in vacuum formed materials.

35. Materials Processing & Forming – Vacuum Forming

36. Materials Processing & Forming – Extrusion Materials such as polystyrene, nylon, polypropylene and polythene can be used in a process called extrusion. These are thermoplastics - this means when they are heated and then pressured in a mould they can be formed into different shapes and sections. A machine used to extrude materials is very similar to the injection moulding machine. A motor turns a thread which feeds granules of plastic through a heater. The granules melt into a liquid which is forced through a die, forming a long 'tube like' shape. The extrusion is then cooled and forms a solid shape. The shape of the die determines the shape of the tube.

37. Topic 3.3 Joining methods • What students need to learn • Characteristics, recognition, preparation, processes, application and • advantages/disadvantages of using the following temporary and • permanent methods when joining materials and components: • Temporary • tapping and threading • nuts, bolts and washers • screws • knock down fittings • Permanent • nails • halving joint • butt joint • rebate joint • housing joint • mortise and tenon joint dowel joint • soft soldering • brazing • welding • rivets — snap and pop.

38. PVA Used for: Gluing Wood Tensol Cement Used for: Gluing Plastic Epoxy resin / Araldite Used for: Gluing Plastic / Wood / Metal / Ceramic Contact Adhesive Used for: Gluing Plastic / Wood / Metal / Ceramic

39. Topic 3.5 Heat treatment • What students need to learn • Characteristics, preparation, processes, application and advantages/ • disadvantages of using the following heat treatments when altering the • properties of metals: • hardening and tempering • annealing • case hardening.

40. Topic 3.6 Finishing techniques • What students need to learn • Processes, application and advantages/disadvantages of applying the • following finishes to improve the performance, quality and appearance of • manufactured products: • varnish • wax polish • stain • paint • plastic dip-coating • electroplating.

41. Topic 3.7 Manufacturing processes for batch production • What students need to learn • Preparation, application and advantages/disadvantages of the following • when manufacturing products and components: • jigs • patterns.

42. Topic 3.8 Health and safety • What students need to learn • How to understand/describe safe working practices. • How to identify workshop hazards and precautions.

43. Topic 4 Analysing products • Topic 4.1 Specification criteria • What students need to learn • When analysing a product, students should take into account the • following specification criteria: • form — Why is the product shaped/styled as it is? • function — What is the purpose of the product? • user requirements — What qualities make the product attractive to • potential users? • performance requirements — What are the technical considerations • that must be achieved within the product? • material and component requirements — How should materials and • components perform within the product? • scale of production and cost — How does the design allow for scale of • production and what are the considerations in determining cost? • sustainability — How does the design allow for environmental • considerations?

44. Topic 4.2 Materials and components • What students need to learn • Students should identify the materials and/or components used in the • manufacture of a product, including: • the properties and qualities of the materials and/or components • the advantages/disadvantages of the materials and/or components • justification of the choice of materials and/or components. • Note: materials and components are those referenced in Topic 1.

45. Topic 4.3 Manufacturing processes • What students need to learn • Students should identify the processes involved in the manufacture of • products, including: • the stages of the manufacturing process • the advantages/disadvantages of the manufacturing process • justification of the choice of manufacturing process.

46. Topic 5 Designing products • Topic 5.1 Specification criteria • What students need to learn • When designing a product, students should take into account the • following specification criteria: • form — How should the product be shaped/styled? • function — What is the purpose of the product? • user requirements — What qualities would make the product attractive • to potential users? • performance requirements — What are the technical considerations • that must be achieved within the product? • material and component requirements — How should materials and • components perform within the product? • scale of production and cost — How will the design allow for scale of • production and what are the considerations in determining cost? • sustainability — How will the design allow for environmental • considerations?

47. Topic 5.2 Designing skills • What students need to learn • When designing a product, students should be able to respond creatively • to design briefs and specification criteria, including: • clear communication of design intentions using notes and/or sketches • annotation which relates to the original specification criteria.

48. Topic 5.3 Application of knowledge and understanding • What students need to learn • When designing a product, students should be able to apply their • knowledge and understanding of a wide range of materials and/or • components and manufacturing processes to each design idea, including: • the properties of materials and/or components • the advantages/disadvantages of materials and/or components and • manufacturing processes • justification of the choice of materials and/or components and • manufacturing processes.

49. Topic 6Information and Communication Technology

50. Electronic communications between designers, manufacturers, retailers and consumers using email Advantages:- Quick delivery and reply of messages- Convenient- Can contact a group of people at once- No limit on how short or how long the message should be (it would seem ridiculous to send a one line letter to someone in the post, but on email this is acceptable)- Can attach large documents and other files with a click of a button (and without using up resources like paper)- Doesn't use any paper (good for the environment) Disadvantages:- Less social contact with people (social relationships won't be as well developed)- Messages may be misinterpreted easily- Can be easy to make a "typo" and say the wrong thing, or send the email to the wrong person- Access to a computer and the internet is necessary, and this may not be convenient for all people