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DT > 1.1 + 1.2 > Flashcards

1.1 + 1.2 Flashcards

1
Q

mechanical vs physical properties

A

mechanical = properties associated with how a material reacts to an external force

physical = properties associated with the actual make-up or structure of the material

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2
Q

compressive strength

A

the ability to withstand being crushed or shortened by pushing forces (compression)

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3
Q

tensile strength

A

the ability to resist stretching or pulling forces (tension)

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4
Q

bending strength

A

the ability to resist forces that may bend the material

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5
Q

shear strength

A

the ability to resist sliding forces on a parallel plane

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6
Q

torsional strength

A

the ability to withstand twisting forces from applied torque or torsion

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7
Q

hardness

A

the ability to resist abrasive wear such as scratching, surface indentation or cutting

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8
Q

toughness

A

the ability to absorb impact force without fracture

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9
Q

plasticity

A

the ability to be permanently deformed (shape) and retain the deformed shape

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10
Q

ductility

A

the ability to be drawn out under tension, reducing the cross-sectional area without cracking

(stretching a material into a wire)

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11
Q

malleability

A

the ability to withstand deformation by compression without cracking. malleability increases with a rise in temperature

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12
Q

elasticity

A

the ability to be deformed and then return to the original shape when the force is removed

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13
Q

electrical conductor

A

allows the flow of electrical current through the material. a good conductor gives very little resistance to the flow of charge

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14
Q

electrical insulator

A

does not allow the flow of electricity through he material

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15
Q

thermal conductor

A

allows the transfer of heat energy through the material. a material with high thermal conductivity allows the transfer of heat to occur quickly across the material

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16
Q

thermal insulator

A

prevents the transfer of heat through the material

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17
Q

thermal expansion

A

the increase in material volume in response to a heat input

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18
Q

opaque

A

prevents light from travelling through

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19
Q

translucent

A

allows light through but diffuses the light so that objects appear blurred.

(frosted glass)

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20
Q

transparent

A

allows light to pass through easily which means you can see clearly through the material

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21
Q

density

A

the mass of the material in a standard volume of space

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22
Q

fusibility

A

the ability of the material to be fused or converted from a solid to a liquid or molten state, usually by heat. good fusibility is an essential property for a metal being cast

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23
Q

magnetism

A

the natural force between objects that causes the material to attract iron or steels

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24
Q

corrosion/degradation resistance

A

the ability of the material to withstand environmental attack and decay

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25
Q

ferrous metals

A

a metal containing mostly iron and carbon, ferrous metals are magnetic and will rust

  • low carbon steel
  • medium carbon steel
  • cast iron
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26
Q

non-ferrous metals

A

a metal that does not contain iron, non-ferrous metals are not magnetic and do not rust

  • aluminium
  • copper
  • zinc
  • silver
  • gold
  • titanium
  • tin
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27
Q

alloy

A

a metal made of two or more metals, or combining two or more elements, one of which must be a metal
alloys can also be a sub classified as ferrous alloys or non-ferrous alloys

ferrous alloys
- stainless steel
- die steel (tool steel)

non-ferrous alloys
- bronze
- brass
- duralumin
- pewter

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28
Q

aluminium drinks can

A

> malleable which allows the can to be deep drawn into shape

> lightweight which makes it easier to lift and transport; aluminium adds little to the product weight

> a food safe material, which means the user will not be poisoned when drinking form the can

> non-ferrous so will not rust on contact with the liquid in the can

> very easy to recycle and use again for other products because it has a low melting point therefore saving finite resources

> aesthetically pleasing, with a natural silvery colour, which offers a contemporary, clean look to the product

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29
Q

hardwood

A

a wood from broad-leafed (deciduous) trees.
these trees are generally slow growing and lose their leaves in autumn

  • oak
  • ash
  • mahogany
  • teak
  • birch
  • beech
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30
Q

softwood

A

a wood from a coniferous (cone bearing) tree.
these trees are generally fast growing and tend to be evergreen

  • pine
  • spruce
  • Douglas fir
  • redwood
  • cedar
  • larch
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31
Q

manufactured board

A

a man-made wood-based composite material.
manufactured boards are available in much larger sizes than solid wood

  • plywood
  • marine plywood
  • aero ply
  • flexible plywood
  • chipboard
  • MDF
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32
Q

teak outdoor garden bench

A

> contains natural oils resistant to moisture, making it vower weather resistant and unlikely to quickly degrade due to the effects of weathering

> contains natural oils which resist acids and alkalis, meaning the bench is unlikely to degrade due to bird droppings or cleaning detergents

> is aesthetically leasing due to the natural dark brown/ red colour and straight grain

> is hard, meaning it will withstand scratches from items such as buttons people’s jeans when they sit down or move around on the bench

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33
Q

thermoplastic

A

a material which can be repeatedly reheated and reshaped, allowing it to be recycled after its initial use.
thermoplastics have long linear chain molecules held by van Der walls forces

  • LDPE
  • HDPE
  • PP
  • HIPS
  • ABS
  • PMMA
  • PET
  • nylon
  • rigid and flexible PVC
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34
Q

thermosetting polymer

A

a material which hen heated undergoes a chemical change whereby the molecules for rigid cross links.
thermosetting polymers cannot be reheated and reshaped, even at very high temperatures

  • urea formaldehyde (UF)
  • melamine formaldehyde (MF)
  • polyester resin
  • epoxy resin
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35
Q

elastomer

A

a material which at room temperature can be deformed under pressure and then upon release of the pressure, will return to its original shape.
elastomers have weak bonds which allow them to stretch easily.

  • natural rubber
  • polybutadiene
  • neoprene
  • silicone
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36
Q

PET drinks bottle

A

> a thermoplastic which allows I tot be recycled; this is important for a single use product as it means it will not contribute to landfill

> tough - if the user drops the bottle, the contents will not be released

> available in transparent form, which allows the user to see how much drink is left

> impermeable to carbon dioxide, making it ideal for carbonated drinks

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37
Q

melamine formaldehyde kitchen worktop

A

> is a thermosetting polymer with a high melting point, so it will not be affected by hot pans placed on the surface

> is chemical resistant which allows the worktop to be cleaned with detergent

> is hard, which enables the user to clean the surface with a scouring pad without scratching the surface

> can be pigmented to give the kitchen worktop a specific colour to fit with the kitchen aesthetic

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38
Q

neoprene wetsuit

A

> is an elastomer so the wetsuit will stretch and release to fit tightly around the body

> has good degradation resistance so will not be damaged by salt water in the sea

> can be pigmented to give a particular colour choice for the consumer, or to provide a company brand colour option

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39
Q

papers and boards

A

papers and boards ca be described as compliant materials, meaning that they can be scored, folded, and cut with basic tooling to form items such as nets for packaging

  • layout paper
  • cartridge paper
  • tracing paper
  • bleed proof paper
  • treated paper
  • water colour paper
  • corrugated card
  • bleached card
  • mount board
  • duplex card
  • foil backed card
  • laminated card
  • metal effect card
  • moulded paper pulp
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40
Q

corrugated card take-away food box

A

> it is compliant and easy to cut and fold to a box shape using a die cutter

> it is a food safe material - the food will not become contaminated by the corrugated card

> it is an insulating material due to the air pockets within the corrugations, which will help to keep the food warm

> it is a lightweight material which makes it easy carry on a delivery bike

> a food box is a single use product, and corrugated card is easily recycled, so the box should not contribute to landfill

> it is biodegradable, so will not contribute to landfill issues if it is thrown away and not recycled

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41
Q

composites

A

a material comprised of two or more different materials, resulting in a material with enhanced properties

fibre based - CFRP, GRP, fibre concrete

particle based - tungsten carbide, concrete

sheet based - aluminium composite board, engineered wood (glulam)

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42
Q

GRP boat hull

A

> can be manufactured via the lay-up method, allowing complex 3D shapes such as the hull to be created

> can be pigmented to produce a range of colours for improved aesthetics or corporate branding such as racing team colours

> has chemical resistance so will not corrode or decay when in the salty sea water

> is a tough material and able to withstand minor impact from waves etc, without damage

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43
Q

smart material

A

a material whose properties change in response to an input or change in the environment, such as electricity, pressure, temperature or light

  • shape memory alloy
  • thermochromatic pigment
  • thermochromatic film
  • phosphorescent pigment
  • photo chromatic pigment
  • electroluminescent wire
  • piezo electric material
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44
Q

thermochromatic film thermometer

A

> it changes colour in response to temperature change

> the colour change, such as red for hot, makes it easier to read than small numbers or lines as used on traditional thermometers

> it is a non-toxic material, therefore much safer to use than mercury thermometers

> it can be incorporated into a film strip, making it flexible enough to go on to a forehead when taking a temperature reading

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45
Q

modern material

A

a material developed through the invention of new or improved processes.
modern materials are not ‘smart materials’ because they do not react to eternal change

  • kevlar
  • precious metal clay (PMC)
  • high density modelling foam
  • polymorph
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46
Q

material disposal

A

> major consideration for the end of a product’s life

> not only influences the manufacturer’s choice but also the consumer’s

> environmentally aware consumer may choose a product based on its ability to be recycled

example:
aluminium bike frame over a CFRP frame, because although CFRP may have performance advantages, it is difficult to recycle, whereas aluminium has a low melting point

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47
Q

tensile testing (practical workshop test)

A

> clamping materials of the same length and thickness into a vice

> applying a load such as weights to the unclamped end

> see how wuchthe material deflects under the load / how much load each material can bear with the least deflection

> the less deflection the more tensile strength

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48
Q

toughness testing (practical workshop test)

A

> material samples are clamped into a vice

> each sample is then hit with the same force, using a hammer

> tough materials with absorb the impact, whereas brittle materials may bend or even shatter

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49
Q

hardness testing (practical workshop test)

A

abrasive wear
> run a file over the surface of the material, using the same force for each sample

> the material with the fewest scratches is the hardest

resistance to surface indentation
> the material sample is fully supported underneath and the dot punch is placed onto the material surface

> the dot punch is hit once with a hammer, using the same force for each sample

> the smaller the indent, the harder the material

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50
Q

malleability and ductility testing (practical workshop test)

A

> secure the test piece in the vice

> try to bend the testy piece to 90*

> cracks or surface damage on the outside of the bend indicates a lack of ductility

> crack or surface damage to the inside of the bend indicates a lack of malleability

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51
Q

conductivity testing (practical workshop test)

A

electrical
> collect material samples of the same dimensions and, on the top surface, mark a set distance between the two ends of the material sample

> the distance is the spacing for each probe of the multimeter

> place the probes on the distance marks and measure the resistance on the multimeter

> the higher the resistance, the lower the electrical conductivity

thermal
> collect material samples of the same dimensions and measure a set distance from one ned for the thermometer to be placed

> a Bunsen burner is lit under the other end of the material

> record the time it takes for the temperature to reach the set point at the other end of the material

> the shorter the time, the higher the thermal conductivity

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52
Q

corrosion testing (practical workshop test)

A

> all test pieces should be the same size

> materials can simply be placed outside in an area exposed to weather effects and left for a certain length of time

> materials can then be visually inspected for surface corrosion

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53
Q

tensile testing (industrial test)

A

> a standard test piece is placed into a tens-meter machine and held in clamps at each end

> one clamp is fixed and the other moves on a worm drive gear mechanism

> as the worm drive travels at a constant rate, the test piece is put under tension.

> as the test piece is stretched, the load and distance travelled is plotted, giving information on elastic limit, yield point, maximum load and final breaking point after ‘necking’

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54
Q

toughness testing (industrial test)

A

> a notched test piece is held vertically in the vice of the test machine

> a pendulum is released from a set position and swings to strike the test piece

> the energy absorbed by the test piece is calculated form the height the pendulum swings to after it hits the test piece

> the material that absorbs the most impact is the toughest

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55
Q

hardness testing (industrial test)

A

Rockwell test
> a preload is applied to the material sample using a diamond indenter which breaks through just the surface of the material

> the preload is the datum or zero reference position

> an additional load is then applied to the test material and held for a predetermined length of time

> the load is then released and the distance between the preload and the applied load is measured, the smaller the indentation depth the harder the material

Brinell test
> a hardened standard size steel ball is forced into the material’s surface using a pre-set load

> the diameter of the indent in the surface is measured, the smaller the diameter indent the harder the material

Vickers pyramid test
> use a diamond square-based pyramid to indent the surface of the material (diamond is used because it won’t deform under load)

> a microscope is used to measure the size of the indent, the smaller the indent the harder the material

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56
Q

ductility and malleability testing (industrial test)

A

> the test piece is placed into a bending machine and held, supported at the ends

> a mandrel or plunger loads the test piece at the centre and bends it to a predetermined angle, or util the piece fractures

> the material is then inspected fro cracks or defects. cracks on the outside indicate the level of ductility, cracks on the inside indicate the level of malleability

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57
Q

ultrasonic testing (non-destructive)
+ and uses

A

> a transducer generates sound waves which are pulsed into the material.

> the intensity of the reflected sound waves signal is recorded on a display unit

> the sound waves travel through he material and if there are any defects such as cracks in the sound waves’ path, the sound energy will be partially reflected and shown on the display unit

+ can be performed on all types of materials
+ it can be portable
+ has a high accuracy of flaw detection

used for the aerospace industries, and used to check the quality of welds in pips for offshore oil applications

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58
Q

X-ray testing (non-destructive)
uses

A

> an x-ray beam passes through the material and an image is projected onto a display screen

> it allows the observation of tiny details within the material

> the magnified images enable miniature flaws such as voids or hairline cracks to be reliably detected

used to inspect integrated circuits and printed circuit boards and to check for voids in composite materials such as F1 cars or track pursuit cycles where there is a monocoque construction

it can also be used to detect faults in turbine blades or aeroplane engine blocks

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59
Q

electrical conductivity (non-destructive testing)

A

> four small diameter wires are stretched parallel to each other across a non-conductive polymer block, held in place and connected to a copper terminal block

> two leads re attached to the inner wires and two to the outer wires

> the outer leads are connected to a precise current and the two inner leads measure the voltage drop

> ohms law (V=IR) can then be used to measure the resistance

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60
Q

thermal conductivity (non-destructive testing)

A

> using a heat flow meter, a square shaped material test piece is placed between ow temperature controlled plates

> the temperature is increased at a controlled rate and the heat flow through the material is measured by heat flow sensors placed on the surface of the material

> as the material is heated to a specific temperature, the sensors measure and record the rate of thermal conductivity

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61
Q

layout paper

A

thin translucent paper with a smooth surface

  • sketching
  • quick ink
  • technical drawing
  • tracing
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62
Q

cartridge paper

A

off-white paper usually with a slightly textured surface

  • sketching
  • rendering in pencil
  • ink and pastel
  • can be used for printing
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63
Q

tracing paper

A

translucent paper slightly thicker than layout paper

  • for copying images when sketching
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64
Q

bleed-proof paper

A

similar to cartridge paper but has a bleed-proof layer on one side so colours do not run

  • spirit-based marker rendering
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65
Q

treated paper

A

plain paper with a clear binder or dye layer applied to help hold the image on the paper surface and brighten the image. Surface sheen such as high gloss or matt available

  • photographic printing
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66
Q

watercolour paper

A

available in absorbent, smooth, hot-pressed or the more textured cold-pressed and heavily textured rough

  • watercolour painting
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67
Q

corrugated card

A

usually with carton board outer layers and a corrugated middle layer, giving the material the ability to provide protection against impact

  • protective packaging
  • model making
  • prototyping ideas
  • food packaging such as take-away boxes
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68
Q

bleached card

A

chemically treated to brighten the surface to make it stable for high-quality printing

  • greeting cards
  • high-quality packaging
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69
Q

mount board

A

made from compressed fine cotton fibres to produce rigid board

  • presenting artwork
  • picture mounting
  • modelling
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70
Q

duplex card

A

made up of two layers of paper, with the exterior often coated to make it more water-resistant and to give it a glossy sheen and waxy feel

  • food packaging such as juice or milk cartons
  • disposable cups
  • plates
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71
Q

foil backing and laminated card

A

card with polymer film or foil applied to either one side or both sides to provide a water resistant and/or heat insulating layer. The foil or laminate layer must be removed before recycling the paper pulp

  • drinks packaging
  • milk cartons
  • take-away box lids
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72
Q

metal effect card

A

high-quality card with a thin metal effect layer applied to the outer surface doe enhanced aesthetics. Can be embossed

  • gift boxes and packaging
  • high-quality metal effect business cards
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73
Q

moulded paper pulp

A

recycled paper pulp moulded when wet and dried to a specific shape. Usually smooth on the visible inside surface and rough textured on the outer surface

  • moulded packaging products
  • eco-friendly packaging
  • egg boxes
  • fruit packaging
74
Q

foam board

A

two outer layers of card with a foam middle core, available in a range of thicknesses

  • mood board backing
  • presentation board
  • modelling
75
Q

fluted PP sheet

A

extruded sheet with integral ‘flutes’ or corrugations. Lightweight and easily bent along the flutes

  • signs (construction site, sales boards)
  • storage box construction
  • portfolio cases
  • small models
76
Q

translucent PP sheet

A

an extremely tough polymer sheet. Can be scored before bending to produce a plastic hinge, which can be folded may times. Virtually impossible to tear, water resistant

  • packaging products
  • folders
  • boxes
77
Q

styrofoam

A

dense, closed cell foam, commonly blue in colour. Can be cut, shaped and sanded with standard workshop tools

  • product modelling
  • formers for modelling and laminating
78
Q

LDPE sheet

A

tough, available in thin sheet form, transparent, good chemical resistance, flexible

  • food wrapping
  • air pillow packaging
  • bubble wrap
  • carrier bags
79
Q

plastazote foam

A

closed cell polyethylene foam, tough, flexible, good impact resistance, impermeable to liquids

  • protective packaging
  • swimming floats
  • gym and exercise mats
  • sound and pipe insulation
  • stage props
80
Q

cellulose acetate

A

transparent, tough, naturally biodegrades

  • packaging film
  • membranes
  • photographic film
81
Q

polylactide

A

transparent, tough, naturally biodegrades

  • biodegradable packaging film
82
Q

air seasoning

A

> traditional and inexpensive method which involves stacking the wood under a shelter, protected from the rain

> air circulate between the planks to slowly remove the excess moisture

> air-seasoned wood is used for outdoor wooden products because it is seasoned to the same moisture content as its surroundings and therefore the wood will be less prone to defects

83
Q

kiln seasoning

A

> a more expensive but controlled method which is very quick and can take just a few weeks

> planks are stacked onto trolleys and placed in the kiln where both temperature and humidity are controlled

> initially, the kiln atmosphere is very steamy but tis is gradually changed to become hotter and drier

> indoor products such as furniture will use kiln seasoned wood because it has been seasoned to meet indoor conditions and will have a lower moisture content than air-dried wood

84
Q

advantages from seasoning

A

+ greater immunity from decay and increase resistance to rot
+ increased strength ad stability
+ helps preservatives to penetrate
+ makes wood less corrosive to metal

85
Q

oak

A

hard, tough, attractive grain, good wether resistance. Contains tannic acid which will corrode steel screws or fixings

  • furniture
  • flooring
  • boat building
  • cladding
  • interior and exterior joinery
86
Q

ash

A

hardwood
tough, attractive open grain pattern which makes it more flexible

  • tool handles
  • ladders
  • sports goods
  • laminating
87
Q

mahogany

A

hardwood
can contain interlocking grain, making it more difficult to work. Rich dark red colour

  • indoor furniture
  • shop fittings and cabinet
  • veneers commonly used on manufactured boards
88
Q

teak

A

hardwood
hard, tough, straight grain, natural oils resist moisture, acid and alkalis

  • outdoor furniture
  • laboratory benches
  • traditional boat decks
89
Q

birch

A

hardwood
hard, straight close grained, resists warping

  • furniture
  • indoor panelling
  • veneers used for birch-faced plywood construction
90
Q

beech

A

hardwood
tough, close grained, hard, available in steamed (white) and un-steamed (pink tinge), does not impart a taste of food

  • chairs
  • chopping boards
  • tools (mallets)
  • steam-bent laminated furniture
  • turned bowls
91
Q

pine (European redwood)

A

softwoods
straight grain, knotty, can contain resinous knots

  • construction work
  • roof beams and timber frame construction
  • interior joinery
92
Q

spruce

A

softwoods
straight grain, resistant to splitting

  • indoor furniture
93
Q

Douglas fir

A

softwoods
straight or slightly wavy grain, few knots, stable, good resistance to corrosion

  • veneers
  • plywood construction
  • joinery and construction work
94
Q

larch

A

softwood
hard, tough, attractive grain pattern fades to silver upon exposure outside, good resistance to moisture

  • garden furniture
  • cladding
  • decking
  • fencing
95
Q

cedar

A

softwood
straight grain, can corrode ferrous metals due to acidic nature, low density, good sound damping, good resistance to moisture

  • exterior cladding
  • sheds
  • greenhouses
  • beehives
  • interior panelling
96
Q

plywood

A

manufactured board
thin layers of wood are place at glee at 90* to each other and are compressed to form the board. Good strength in all directions, no grain weaknesses, always has an odd number of layers

  • structural work
  • desk tops
  • indoor furniture
  • floorboards
97
Q

marine plywood

A

manufactured board
similar construction to plywood but it is gap and void free and uses specialist water and boil proof glue to provide resistance to moisture. Some higher quality marine plywood is also resistant to fungal attack

  • boat dashboards
  • boat lockers and panelling
98
Q

aeroply

A

manufactured board
plywood made froh high quality timber such as birch. Available in very thin sheets, lightweight, easy to bend around a support frame

  • gliders
  • laminated furniture
  • laser cut projects
  • jewellery items
99
Q

flexible plywood

A

manufactured board
an odd number of layers glued together with the two outer layers made form open grained timber which allows the sheet to flex. Bent and glued around a former to achieve a solid shape

  • laminated furniture
  • curved panels
100
Q

chipboard

A

manufactured board
wood chips compressed with a resin such as urea formaldehyde

  • often veneered or covered in polymer laminate
  • kitchen worktops and units
  • shelving and flat pack furniture
101
Q

MDF

A

manufactured board
compressed wood fibre, although sometimes urea formaldehyde is added as an additional resin. It has two smooth faces, available in either standard grade or veneered with a layer of timber

  • model making or mould making
  • furniture items such as bookcases
  • cabinets and desks
102
Q

veneers

A

thin slices of wood less than 3mm thick

  • decorative coverings for manufactured board
103
Q

MF laminates

A

thin sheets of MF polymer, hard, tough, chemical resistant

  • decorative covering for chipboard for kitchen worktops etc
104
Q

toxicity of wood

A

> dust and sap from woods can be hazardous and form a health risk for manufacturers as well as those in the vicinity

> under COSHH regulations 2002, both hard and soft wood dust exposure limits of 5mg per cubic metre

> can cause respiratory irritation and hardwood dust is listen as carcinogenic

> employers should ensure that this is adequate PPE extraction and ventilation systems in place, and that exposure levels for workers are reduced

105
Q

rough sawn

A

> available in 32mm thick or 50mm thick pieces

> the wood comes directly from seasoning and has rough surfaces produced from initial conversion

> rough sawn wood will have nominal sizes rather than accurate finished sizes

> cheaper than planed all round

106
Q

planed square edge

A

> wood has only one edge that is planed accurately, the rest are rough sawn

> planing removes about 3mm from the original nominal size

107
Q

planed all round

A

> wood has sides and edges that are all planed square, straight and level, leaving a smooth finish and is ready to use

> the planed all round board is about 3mm smaller all round than the original rough sawn nominal size

108
Q

natural wood

A

> natural wood is only available at the maximum width of the tree

> to produce a wide desk top, natural wood planks need to be joined together

> when joining planks of wood together, the end grains must go in opposing directions to each other

> this is to ensure that the internal forces of the wood do not pull the wood in one direction, and the top is joined in equilibrium

109
Q

manufactured boards advantages to manufacturer

A

+ available in long, wide boards of uniform thickness and quality
+ very stable, not affected by temperature and humidity as much as solid wood
+ uniform strength across the board, no grain problems
+ difficult to split and available in flexile thin sheet form
+ generally less expensive than solid wood of a similar size
+ veneers can be applied to the surface for enhanced aesthetics

110
Q

mouldings

A

some wood is made into mouldings such as skirting boards or wooden trims and are readily available in standard lengths up to approximately 4m

111
Q

metal ores

A

copper = chalcopyrite

aluminium = bauxite

tin = cassiterite

zinc = zinc blende

112
Q

aluminium

A

non-ferrous
lightweight, ductile, malleable, corrosion resistant, electrical and thermal conductor, can be metal inert gas and tungsten inert bas heat welded

melting temperature 660 *C

  • drinks cans
  • aircraft bodies
  • bike frames
  • window frames
  • packaging
  • baking foil
113
Q

copper

A

non-ferrous
ductile, malleable, tough, corrosion resistant, goof electrical ad thermal conductor, can be soldered and brazed

melting temperature 1083 *C

  • electrical wire
  • printed electrical circuits
  • water pipes
  • hot water tanks
  • central heating planks
114
Q

zinc

A

non-ferrous
low melting point, good corrosion resistance

melting temperature 420 *C

  • galvanising steel as a protective coating for dustbins
  • buckets
  • farm gates
  • intricate die castings
115
Q

silver

A

non-ferrous
malleable, ductile, corrosion resistant, can be soldered

melting temperature 962 *C

  • jewellery
  • cutlery
  • used for plating other materials
116
Q

gold

A

non-ferrous
malleable, ductile, corrosion resistant, can be soldered

melting temperature 1063 *C

  • jewellery
  • electronic components
  • connectors
  • switch components
117
Q

titanium

A

non-ferrous
hard, similar strength to steels but more lightweight, high resistance to corrosion

melting temperature 1668 *C

  • joint replacements
  • tooth implants
  • spectacle frames
  • aircraft
  • spacecraft
  • golf clubs
  • bicycles
  • ship hulls
118
Q

tin

A

non-ferrous
ductile, malleable, low melting point, corrosion resistant

melting temperature 232 *C

  • soft solder
  • coatings for food cans
  • rarely used in pure form
119
Q

low carbon steel

A

ferrous
ductile, high tensile strength, tough, malleable, poor resistance to corrosion

0.15 - 0.30 % carbon content

melting temperature 1427 *C

  • nuts
  • bolts
  • washers
  • screws
  • car bodies
  • outer panels for white goods
120
Q

medium carbon steel

A

ferrous
harder than low carbon steel but less ductile, malleable and tough

0.30 - 0.70 % carbon content

  • springs
  • gardening tools (trowels, forks)
121
Q

cast iron

A

ferrous
hard outer skin but brittle core, good under compression

3.5 % carbon content

melting temperature 1149 *C

  • disc brakes
  • machine parts
  • engine blocks
  • sheet furniture such as decorative bollards, bins and lighting
122
Q

stainless steel

A

ferrous alloy
tough, hard, corrosion resistant

18% chrome 8% nickle

melting temperature 1520 *C

  • sinks
  • kitchenware
  • cutlery
123
Q

high speed steel

A

ferrous alloys
hard, tough, high level of resistance to frictional heat

18% tungsten 4% chromium 1% vanadium 0.5-0.8% carbon

  • tool blades
  • drill bits
  • milling cutters
  • router bits
124
Q

die steel (tool steel)

A

ferrous alloy
hard, tough

  • blanking punches and dies
  • extruder dies
  • fine press tools
125
Q

bronze

A

non-ferrous alloy
tough, corrosion resistant, can be cast

90% copper 10% tin

melting temperature 850-1000 *C

  • statues
  • coins
  • bearings
126
Q

brass

A

non-ferrous alloy
corrosion resistant, good electrical and thermal conductor, low melting point, casts well

65% copper 35% zinc

melting temperature 930 *C

  • boats fittings
  • door furniture
  • cast valves and taps
  • ornaments
127
Q

duralumin

A

non-ferrous alloy
equivalent strength properties to low carbon steel but more lightweight, ductile, becomes harder as it is worked

4% copper % magnesium 95% manganese

  • aircraft parts
  • vehicle parts
128
Q

pewter

A

non-ferrous alloy
malleable, low melting point, casts well

85-99% tin remainder copper and antimony

melting temperature 170-230 *C

  • tankards
  • flasks
  • goblets
  • photos frames
  • decorative items
  • candlesticks
  • sports trophies
129
Q

sheet (stock form)

A

sheet is large flat sections of metal in varying thicknesses from less than 1mm up to 3mm

130
Q

plate (stock form)

A

plate is generally thicker than 3mm and narrower than sheet metals

131
Q

bar (stock form)

A

bar is a solid form, flat bar, square bar, round bar, or hexagonal bar

132
Q

tube (stock form)

A

tube form is hollow in cross section and can be square, rectangular, round or hexagonal

133
Q

structural (stock form)

A

angular shapes such as H beams, L beams (angle), I beams, tee bar and channel

134
Q

LDPE

A

thermoplastic
very tough, good chemical resistance, weatherproof, available in translucent, low level of rigidity

safe working temperature 65 *C

  • squeeze detergent bottle
  • toys
  • carrier bags
  • bin liners
  • general packaging
  • food wrap film
  • food trays
135
Q

HDPE

A

thermoplastics
available in translucent form, weatherproof, tough, good chemical resistance

safe working temperature 65 *C

  • chemical drums
  • jerry cans
  • toys
  • household and kitchenware
  • long life carrier bags
  • buckets
  • bowls
136
Q

polypropylene

A

thermoplastics
available in translucent, good chemical resistance, tough, good fatigue resistance (hinge property)

safe working temperature 100 *C

  • rope
  • folders
  • folio cases
  • food containers
  • medical equipment
  • hinged container lids
137
Q

high impact polystyrene

A

thermoplastics
hard, rigid, available in translucent, tough

safe working temperature 70 *C

  • yoghurt pots
  • refrigerator linings
  • single use drink cups
  • toilet seats
  • instrument control knobs
138
Q

acrylonitrile butadiene styrene (ABS)

A

thermoplastics
extremely tough, hard, available in opaque

safe working temperature 80 *C

  • telephone handsets
  • rigid luggage
  • domestic appliances (food mixers)
  • handles
  • computer housings
  • remote control casings
  • calculator casings
139
Q

polymethyl-methacrylate

A

thermoplastic
tough, hard, good chemical resistance, available in translucent

safe working temperature 95 *C

  • car light casings
  • CNC laser cut items
  • lighting units
  • lighting covers
  • baths
140
Q

nylon

A

thermoplastics
tough, corrosion resistant, good temperature resistance, low coefficient of friction

safe working temperature 150 *C

  • bearings
  • gears
  • curtain rails
  • textiles
  • boil-in-the-bag food packaging
  • car engine manifolds
  • cable ties
141
Q

rigid polyvinyl chloride (uPVC)

A

thermoplastics
rigid, opaque, tough, hard, good weathering resistance, good chemical resistance, fire retardant

safe working temperature 95 *C

  • window frames
  • external doors
  • guttering and downpipes for buildings
  • water service pipes
  • bank cards
142
Q

flexible polyvinyl chloride (PVC)

A

thermoplastic
available in translucent, tough, flexible, good weathering resistance, good chemical resistance

safe working temperature 95 *C

  • hose pipes
  • cable insulation
  • medical grade tubing
  • inflatable products
  • imitation leather
  • seat coverings
143
Q

urea formaldehyde

A

thermoset
hard, heat resistant, good electrical insulator, brittle

safe working temperature 80 *C

  • electrical fittings
  • adhesives
144
Q

melamine formaldehyde

A

hard, opaque, tough, heat resistant, food safe, chemical resistant

safe working temperature 130 *C

  • decorative laminates
  • picnic ware
  • buttons
145
Q

polyester resin

A

thermoset
rigid, heat resistant, chemical resistant, brittle

safe working temperature 95 *C

  • castings
  • used in lay-up process for GRP for boat hulls
  • car parts
  • chair seats
146
Q

epoxy resin

A

thermoset
rigid, clear, hard, tough, chemical resistant

safe working temperature 80-200 *C

  • adhesives
  • surface coatings
  • encapsulation of electrical components
  • cardiac pacemakers
  • aerospace applications
  • used in lay-up techniques with carbon fibre reinforced plastic
147
Q

natural rubber (polyisoprene)

A

elastomer
high tensile strength, low elongation, good hardness compared to other elastomers, tough, electrical insulator, good cold resistance

  • automative industry such as tyres
  • tubes
  • hoses
  • gaskets
  • belts
  • balloons
  • toys
  • footwear
148
Q

butadiene rubber

A

elastomer
tough, excellent wear resistance against friction, good thermal resistance against friction, electrical insulator

  • vehicle tyres
  • shoe soles
  • toys
  • conveyor belts
  • water and pneumatic hoses
149
Q

neoprene (polychloroprene rubber)

A

elastomer
good thermal resistance, toughness, good oil and chemical resistance, excellent weather resistance, good abrasion resistance, electrical insulator

  • wetsuits
  • laptop cases
  • industrial wire insulation
  • automative applications such as shock absorber seals
  • hose covers
  • transmission belts
  • gaskets
  • door seals
150
Q

silicone

A

good flexibility at low temperatures, poor abrasion resistance, good thermal resistance and resistance to temperature extremes, good weather resistance, good lubricating qualities, electrical insulator

  • flexible ice cube trays
  • bakeware
  • cooking utensils
  • seals for refrigerators
  • machinery lubricant
  • sealants
  • mould making
  • medical uses such as lubricants for prosthetics
  • tubing for drug delivery systems
151
Q

biodegradable polymer

A

> made form finite resources such as crude oil

> contains additives that cause it to degrade quicker

> degradation occurs because of the action of micro-organisms that convert the material into water, CO2, biomass and methane (CH4)

152
Q

oxy-degradable polymer

A

> polymer breaks down into a fine powder with exposure to oxygen

> the length of time for polymers to degrade can be ‘programmed’ during the manufacture and ranges from a few moths to a few years

> commonly used for LDPE carrier bags which results in the carrier bag breaking down into small confetti shoes and then into powder

153
Q

photodegradable polymer

A

> the polymer bonds are weakened and the polymer breaks down with exposure to UV light such as sunlight

> often used in the agriculture industry where the ground is covered by the polymer sheet to prevent weed growth when growing crops

> as the sheet slowly degrades, weed growth halts, therefore decreasing the need for herbicides

> the sheet also helps hold water in the ground and extends the growing season by inflating the ground

154
Q

hydro-degradable polymer

A

> breaks down with exposure to water

> tend to degrade more quickly than oxy-degradable polymers

> the additive is often used in liquid detergent sachets for household use in washing machines or dishwashers

> particularly useful where there is a risk of cross contamination such as n chemical plants or hospitals

155
Q

implications of bio-polymers and biodegradable polymers

A
  • can produce methane gas when they decompose in landfill (contribute to global warming)
  • can take high temperatures to decompose and may leave behind toxic residue
  • need land to grow crops, which takes land from other crops
  • natural bio-polymers could be made from genetically modified crops
  • cannot be recycled (contribute to a throw-away culture)
156
Q

corn starch polymer

A

bio-polymer (natural)
made from high starch vegetables such as corn, potatoes and maize

  • packaging products
  • straws
  • vending cups
  • disposable cutlery
  • bags
  • take-away food containers
157
Q

potatopak

A

bio-polymer (natural)
made from potato starch

  • single use food item such as bowls
  • cutlery
  • food trays
  • serviettes
  • packaging beads
  • bin bags
158
Q

biopol

A

bio-polymer (natural)
made from bacteria grown in cultures
additive to promote degradation
1% added to thermoplastics

  • packaging products such as film
  • carrier bags
  • vending cups
  • nappies
  • surgical stitches
  • pill coverings
159
Q

polylactide acid (PLA)

A

bio-polymer (synthetic)
made form corn kernels or cane sugar, fermented to produce lactic acid, then synthesised to produce polylactic acid

  • packaging
  • single use bottles
  • carrier bags
  • plant pots
  • disposable nappies
  • medical sutures
  • 3D printing
160
Q

polyhydroxyalkanoate (PHA)

A

bio-polymer (natural)
made form bacteria grown in cultures
fully compostable

  • packaging
  • medical uses such as slow release medication patches
  • films
  • screws and bone plates
161
Q

lactide

A

bio-polymer (synthetic)
fully compostable, water soluble
PLA and cellulose based

  • biomedical applications
  • slow release medication
  • bone repair fixings
  • detergent washing sachets
162
Q

glycolide

A

bio-polymer (synthetic)
fully compostable
PLA and cellulose based

  • food film
  • bags
  • packaging wrap
  • bin bags
  • agriculture ground sheet
  • flower wrap
163
Q

CFRP

A

carbon fibres mixed with polyester eosin or expose resin
lightweight, corrosion resistant, tough, hard, good compressive strength, low thermal expansion

  • sports equipment such as bicycle frames
  • tennis racquets
  • fishing rods
  • racing car bodies and parts
  • helmets
  • prosthetics
164
Q

GRP

A

glass fibres mixed with polyester resin
lightweight, corrosion resistant, tough, hard, low thermal expansion, good compressive strength

  • boat hulls
  • pond liners
  • kayak shells
  • sports car bodies and parts
  • locomotive train cabs
165
Q

tungsten carbide

A

ceramic tungsten and cobalt metal
hard, tough, resistant to high temperatures, corrosion resistant

  • cutting tools such as drill bits
  • lathe tool tips
  • router bits
  • kitchen knives
166
Q

aluminium composite board

A

aluminium sheets with a polyethylene core
lightweight, rigid, tough, malleable, good thermal and sound insulation, good vibration damping

  • sound-proofing panels in cars
  • buildings and boats
  • signage
167
Q

concrete

A

cement powder, sand, aggregate particles mixed with water
high compression strength, low tensile strength, few surfaces defects, easy to mould

  • pathways
  • beams
  • blocks
  • driveways
  • house foundations
168
Q

reinforced concrete

A

cement powder, sand aggregate particles and low carbon steel rods mixed with water
high compression and tensile strength, consistency across the structure, few surface defects, fire resistance

  • buildings
  • bridge piles and bridge spans
  • retaining walls
  • grid floors
169
Q

fibre cement

A

cement powder, sand, aggregate particles and polymer or steel fibres mixed with water
lighter in weight than reinforced concrete, hard, tough, good at low temperatures and freeze/thaw situations

  • suspended floors
  • complex geometric shapes
  • pathways
170
Q

engineered wood e.g glulam

A

timber laminates and MF adhesive
good aesthetics, natural alternative to reinforced concretes, more lightweight than concrete alternatives, fire resistant, good structural stability, corrosion proof

  • beams
  • bridges
  • domes
  • arches
  • decking
  • roof beams
  • rafters
171
Q

shape memory alloy e.g nitinol

A

changes shape in response to a change in temperature or electrical input

  • dental braces
  • self closing windows
  • aeroplane
  • wing flaps
  • bioengineering such as stents, bone plates and screws
172
Q

thermochromic pigment

A

changes colour in response to temperature change

  • room thermometers
  • medical thermometers for children
  • bath water thermometers
  • colour change mugs and kettles
  • food packaging
  • baby feeding spoons
  • battery charge indicator strips
173
Q

phosphorescent pigment

A

absorbs light energy during the day and ‘re-emits the light energy when it is dark

  • fire exit signs
  • glow in the dark products
  • masks
  • night lights
  • watch hands
174
Q

photochromic pigment

A

changes colour with light intensity

  • welding goggles
  • reactive spectacle lenses
  • security markers that show under UV light
175
Q

electroluminescent wire

A

thin copper wire coated in a phosphorescent material which glows in response to an alternating current

  • glow bracelets
  • interweaving for clothing
  • home decoration
  • outdoor decorative lighting
176
Q

piezoelectric material

A

gives off a small electrical charge when deformed
increases in size up to 4% when an electrical current is passed through it

  • airbag sensors in cars
  • lighters
  • vibration damping in tennis racquets
  • musical greeting cards
  • pressure sensors
177
Q

kevlar

A

aramid fibres with high cut and heat resistant properties

  • body armour
  • cut-proof gloves and aprons
  • aerospace applications
  • surfboard components
  • puncture resistant bicycle tyres
178
Q

precious metal clay (PMC)

A

clay consistency material made up of fine metal particles.
works like ceramic clay, mouldable, sets hard once fired, inexpensive compared to solid metals such as silver

  • jewellery
  • decorative items
  • small sculptures
  • fobs
179
Q

high density modelling foam

A

polyurethane closed cell foam blocks or sheets
lightweight, easy to work using traditional woodworking tools, CNC router, sands easily to allow intricate shapes and forms to be created

  • 3D modelling
  • prototypes
180
Q

polymorph

A

granules which become mouldable at about 60C
can be heated in water or with a hair dryer, solidifies at room temperature, also available in liquid form (liquid at room temperature and solidifies at 2C)

  • modelling
  • shaping ergonomic handles
  • prototype mechanical parts

DT (2 decks)

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