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(A-Level) Product Design > Metals > Flashcards

Metals Flashcards

1
Q

How does a Blast Furnace work?

A
  1. Solid raw materials - iron ore, coke, limestone - are added from the top of the blast furnace
  2. Hot air is blown into the bottom of the blast furnace and provides the oxygen for the coke (carbon) to burn.
  3. Iron oxide in the iron ore reacts and changes to iron. Molten iron trickles to the bottom of the furnace.
  4. Limestone reacts with impurities to form a slag that floats on the iron.
  5. Waste ages are removed to a treatment plant.
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2
Q

What are the 3 types of metals

A

There are 3 types of metals:

  • Ferrous
  • Non-Ferrous
  • Alloys (you can have ferrous and non-ferrous alloys)
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3
Q

What are qualities of Ferrous Metals

A
  • Ferrous metals are metals which contain iron.
  • They will corrode if unprotected
  • Ferrous metals will be attracted by a magnet
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4
Q

How Do We Extract Aluminium and Copper

A

Aluminium is the most plentiful metal found in the earth’s crust and is high demand because it is light and strong. It is also very expensive, as it undergoes electrolysis (an expensive process) to get pure aluminium.

Aluminium is extracted from aluminium oxide (bauxite) by electrolysis. Electricity passes between the electrodes and pure aluminium forms at the cathode.

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5
Q

How are the Qualities of Iron improved

A

When carbon (a very hard, brittle element) is mixed with the iron the characteristics (properties) of iron are greatly improved. The result is a harder and tougher material - steel.

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6
Q

What effect does higher carbon content have when being added to iron

A
  • The material becomes harder
  • Toughness reduces - cast iron is brittle under impact
  • Both medium and high carbon steel can be heat treated to make them harder and stronger
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7
Q

What is the Structure of Metals

A
  • All metals are made up of crystals. Each crystal has a boundary that is firmly bonded to the boundary of a neighbouring crystal.
  • The nature of the crystal depends very much on the material.

(For example, steel is made up of iron and carbon so these elements will be seen within the microstructure of the material.)

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8
Q

How Available are Metal Ores (and how sustainable are they?)

A
  • 25% of the earths crust is made up of metal ores
  • Aluminium is the most common ore, followed by iron
  • In general, the more rare the material the more expensive it is (however aluminium which is a common ore is expensive to process as you have to use electrolysis rather than heat)
  • The ores do not re-grow when we dig them up meaning metals are non renewable and unsustainable
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9
Q

Types of Ferrous Metals

A
  • Cast Iron
  • Low Carbon Steel
  • High Carbon Steel
  • High Speed Steel (HSS)
  • Medium Carbon Steel
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10
Q

Types of Non-Ferrous Metals

A
  • Aluminium
  • Zinc
  • Copper
  • Silver
  • Gold
  • Titanium
  • Tin
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11
Q

Types of Ferrous Alloys

A
  • Stainless Steel
  • Die Steel (tool steel)
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12
Q

Types of Non-Ferrous Alloys

A
  • Brass
  • Bronze
  • Pewter
  • Duralumin
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13
Q

What are some Performance Characteristics of Metal (get around 6)

A
  • Hardness
  • Toughness
  • Malleability
  • Elasticity
  • Tensile Strength
  • Density
  • Resistance to corrosion
  • Thermal Conductivity
  • Electrical Conductivity
  • Melting Points
  • Ability to be alloyed
  • Ability to be joined with heath processes
  • Ability to take applied coatings and finishes
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14
Q

Properties/Characteristics and Uses of Low Carbon Steel

A

Properties/Characteristics:
- Ductile, high tensile strength, tough, malleable, poor resistance to corrosion.
- 0.15-0.30% Carbon content
- Melting Temp: 1,427°C.

Uses:
Nuts, washers, screws, bolts, car bodies, outer panels for white goods

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15
Q

Properties/Characteristics and Uses of High Speed Steel (HSS)

A

Properties/Characteristics:
- Hard, tough, high level of resistance to frictional heat.
- 18% tungsten, 4% Chromium, 1% vanadium, 0.5-0.8% Carbon
- Melting Temp: 1430°C

Uses:
Tool blades, drill bits, milling cutters, router bits

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16
Q

Properties/Characteristics and Uses of Medium Carbon Steel

A

Properties/Characteristics:
- Harder than low carbon steel, but less ductile, malleable tough.
- 0.30-0.70% Carbon content
- Melting Temp: 1520°C

Uses:
Springs, gardening tools

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17
Q

Properties/Characteristics and Uses of Cast Iron

A

Properties/Characteristics:
- Hard outer layer but brittle at core, good under compression.
- 3.5% Carbon
- Melting Temp: 1,149°C

Uses:
Disc brakes, machine parts, engine blocks; sheet furniture, for example decorative bollards, bins and lighting

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18
Q

Properties/Characteristics and Uses of Aluminium

A

Properties/Characteristics:
- Lightweight, ductile, malleable, corrosion resistant, electrical conductor, thermal conductor, can be metal inert gas (MIG) and tungsten inert gas (TIG) heat welded.
- Melting Temp: 660°C

Uses:
Drinks cans, aircraft bodies, bike frames, window frames, packaging, baking foil

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19
Q

Properties/Characteristics and Uses of Copper

A

Properties/Characteristics:
- Ductile, malleable, tough, corrosion resistant, good electrical conductor, good thermal conductor, can be soldered and brazed.
- Melting Temp: 1,083°C

Uses:
Electrical wire, printed electrical circuits, water pipes, hot water tanks, central heating pipes

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20
Q

Properties/Characteristics and Uses of Zinc

A

Properties/Characteristics:
- Low melting point, good corrosion resistance.
- Melting Temp: 420°C

Uses:
Galvanising steel as a protective coating for dustbins, buckets, farm gates; intricate die castings

21
Q

Properties/Characteristics and Uses of Silver

A

Properties/Characteristics:
- Malleable, ductile, corrosion resistant, can be soldered.
- Melting Temp: 962°C

Uses:
- Jewellery, cutlery, used for plating other materials

22
Q

Properties/Characteristics and Uses of Gold

A

Properties/Characteristics:
- Malleable, ductile, corrosion resistant, can be soldered.
- Melting Temp: 1,063°C

Uses:
- Jewellery, electronic components, connectors, switch components

23
Q

Properties/Characteristics and Uses of Titanium

A

Properties/Characteristics:
- Hard, similar strength to steel but more lightweight, high resistance to corrosion.
- Melting Temp: 1,668°C

Uses:
- Joint replacements, tooth implants, spectacle frames, aircraft, spacecraft, golf clubs, bicycles, ship hulls

24
Q

Properties/Characteristics and Uses of Tin

A

Properties/Characteristics:
- Ductile, malleable, low melting point, corrosion resistant.
- Melting Temp: 232°C

Uses:
- Soft solder, coatings for food cans, rarely used in pure form

25
Q

Properties/Characteristics and Uses of Stainless Steel

A

Properties/Characteristics:
- Tough, hard, corrosion resistant.
- 18% chrome, 8% nickel
- Melting Temp: 1,510°C

Uses:
- Sinks, kitchenware, cutlery

26
Q

Properties/Characteristics and Uses of Die Steel (Tool Steel)

A

Properties/Characteristics:
- Hard, tough.
- 1% Silicon, 0.40-0.55% Carbon, 0.4% Molybdenum, 0.4% Manganese
- Melting Temp: 1,427°C

Uses:
- Blanking punches and dies, extruded dies, fine press tools

27
Q

Properties/Characteristics and Uses of Bronze

A

Properties/Characteristics:
- Good hardness and brittleness, high resistance to corrosion.
- 88% copper, 12% tin
- Melting Temp: 913°C

Uses:
- Boats and ships, sculptures, musical instruments, electrical connectors, bearings

28
Q

Properties/Characteristics and Uses of Brass

A

Properties/Characteristics:
- High corrosion resistance, malleable, susceptibility to cracking under stress, highly castable, good thermal conductivity.
- 90% copper, 10% tin
- Melting Temp: 930°C

Uses:
- Decoration, musical instruments, plumbing pipes and tubes

29
Q

Properties/Characteristics and Uses of Duralumin

A

Properties/Characteristics:
- Relatively soft, ductile, and workable, lightweight, high strength per unit weight, can be rolled, forged, and extruded.
- 90% aluminium, 4% copper, 0.5%-1.0% manganese
- Melting Temp: 660°C

Uses:
- Aircrafts, frames of speed boats, pressure cookers, lightweight guns

30
Q

Properties/Characteristics and Uses of Pewter

A

Properties/Characteristics:
- Good malleability, good ductility, can be easily bent and hammered
- 92% tin, 6-7% antimony, and 1-2% copper
- Melting Temp: 290°C

Uses:
- Dishes, church vessels, decorative items, kettles, mugs

31
Q

Reasons for applying a finish to a metal

A
  • Protecting the material against corrosion
  • Making the product water repellent
  • Improving its resistance to wear and light
  • Improving its ability to reflect or absorb heat
  • Improving its ability to insulate against heat or electricity
32
Q

What is Electroplating?

A

Electrochemical process that allows ions from the coating material to form on the base material, giving it the finish of the coating material. Eg. chromium plating is used to enhance the properties of bathroom taps, kitchen equipment and vehicle components.

33
Q

What is Anodising

A

Aluminium can be anodised, this process makes the surface of the aluminium more durable and resistant to scratches. Anodising is produced in an electrochemical cell where a sulphuric acid = electrolyte, aluminium product = anode, lead = cathode. passing and electrical current through the electrolyte builds up a tough oxide layer.

34
Q

What is Enamelling

A

Finely ground glass formed into a water based slurry, is sprayed onto metal components, eg. cooker components. it is then fired so the coating becomes a continuous layer of heat and scratch resistant material.

35
Q

What is Powder Coating

A

A method of applying paints to a product that has been statically charged. it is a dry process, which uses powder not paint. The powder is sprayed through an airgun that is positively charged, and the product is negatively charged, therefore there is a strong attraction between the two. Once coated the product is baked, melting the powder and producing a harder and tougher finish than paint. It is an environmentally sound method as no solvents are used and the excess can be recovered.

36
Q

What happens in Bead Blasting

A

Involves shooting small spherical particles (like sand, or glass particles) at a surface to clean/prepare a surface (remove any residue from the surface).

It’s used as a preparation process and can be used as a finishing process in its own right.

37
Q

Advantages and Disadvantages of Bead Blasting

A

Advantages:
• It can be used to make a controlled texture/Matt finish
• Can be used to remove burrs and sharp edges of metal parts
• Effective at removing contaminants from surfaces
• It is relatively gentle compared to other methods
• It is used to prepare metals
• Can be used for restoring surfaces

Disadvantages:
• It can generate heat when high pressure or absrasive particles are used
• Thin or lightweight parts may be damaged by the pressures
• It can remove material from the surface (which may affect tolerances)
• Can contaminate the surface
• It is less practical for large and complex parts

38
Q

How would paint be applied to metals commercially

A

A spray painting robotic arm will be programmed to cover all parts of the product with spray paint

39
Q

Advantages and Disadvantages of Paint

A

Advantages:
• Automated, meaning less chance of human error
• Can be used in mass production
• Little excess spray is used
• Highly efficient and consistent

Disadvantages:
• High setup cost
• Machines could break and cause disruption

40
Q

What is Plastic Coating (Powder Coating)

A

It is a process where powder (made up of paint and resin particles). The particles that come out of the gun are given a charge, while the material that is being sprayed is grounded, meaning the particles are attracted to the material, meaning the product is fully covered and consistent.

41
Q

Advantages and Disadvantages of Plastic Coating (Powder Coating)

A

Advantages:
• It can be applied to any material
• Strong, durable, corrosion resistant and cost efficient finish
• Combination of chemical pigments
• There are different levels of gloss and can be customised to give a unique finish
• Resistant to chipping, scratching, and fading
• Powder coating is time efficient and less costly
• Doesn’t produce damaging pollutants and fumes
• Generates less product waste

Disadvantages:
• Difficult to make thin even coatings (easy to make thick even coatings), this can affect tolerances
• The materials used need to withstand curing temperature (need to be heat resistant)
• Has a very high start up costs

42
Q

What is Galvanising and what does it involve?

A

Galvanising involves dipping parts in molten zinc to protect the steel underneath. The zinc bonds itself to the surface of the steel.

This involves cathodic protection, where the zinc is sacrificed to protect the steel underneath

43
Q

Advantages and Disadvantages of Galvanising

A

Advantages:
• Extremely durable (can stay up to 100 years)
• Has a low lifetime cost

Disadvantages:
• The material being galvanised needs to withstand the heat when being dipped
• Is better used for large items

44
Q

Process of Electroplating

A

• Parts are disassembled
• Stripping the metal removes particles which can affect the plate layer
• Polishing refined and evens the surface in preparation for plating
• The object is dipped into cleaning solution and electrified
• The metal is then placed in the plate bath, where plating deposit begins. The longer an object is exposed to a current, the thicker the plating will become
• Then post treatment takes place, in order to prevent tarnishing and improve resistance.

45
Q

Advantages and Disadvantages of Electroplating

A

Advantages:
• Gives a more consistent aesthetic finish
• Coats inside the product effectively
• Is a very thin layer applied, meaning tolerances will not be affected as much
• Enhanced durability

Disadvantages
• It is a long process with many different stages
• It is a complex and expensive process
• Potential for defects

46
Q

Process of Anodising

A
  • The surface of the aluminium product needs cleaning prior to anodising. Exposing the surface uses acidic or alkaline cleaning agents to clean grease/dirt from the surface.
  • Pre-treatment eliminates any surface imperfections. The goal is to provide a visible finish with a clean and smooth surface. This is done by using two main processes – brightening and etching. Brightening cleans any heavy metal residues left over from the cleaning process. Etching removes a layer of aluminium from the product surface to provide a matte finish
  • After pre-treatment, the product is ready for anodising. As mentioned above, sulfuric acid is the go-to electrolyte for aluminium anodising. One method for colouring aluminium is electro colouring. In electrocolouring, the anodised aluminium product is introduced to inorganic metallic salts through an electrolyte. The anodised aluminium product becomes one electrolyte, and graphite (or aluminium) becomes the other.
  • Finally, sealing takes place and is the final step in the aluminium anodising process. This prevents water leakage and improves corrosion resistance to the anodised aluminium product
47
Q

What is Cathodic Protection

A

Cathodic protection is a technique used to control the corrosion of a metal surface by making it the cathode of an electrochemical cell. A simple method of protection connects the metal to be protected to a more easily corroded “sacrificial metal” to act as the anode

48
Q

Advantages and Disadvantages of Enamelling

A

Advantages:
• Gives a very aesthetic finish
• Easy to apply
• Gives a shiny, glossy finish
• Easy to clean

Disadvantages:
• Can be sharp when it chips
• Enamel can become brittle

(A-Level) Product Design (26 decks)

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