Metals

Question 1

Stock forms

5 main

Answer 1

Sheet - large flat section, vary thickness 1mm to 3 mm
Plate - thicker and narrower than sheets
Bar - solid form
Tube - hollow in cross section
Structural angular - H, L and I beams, tee bar and channel

Question 2

CH
Where from
Name 1 ore
After product life

Answer 2

Naturally occurring, mined from ground in form of ore.
25% of earth’s crust is metal ore
Al ore is bauxite
Can be easily recycled due to low melting point

Question 3

Non ferrous - what’s special about them
M Aluminium 650
M titanium 1700

Answer 3

Won’t corrode
Al - drink can, aircraft body, bike frame, saucepans.
Lightweight, ductile, malleable
Corrosion resistant, electrical and thermal conductor

Ti - aircraft, spacecraft, hip or joint replacement,
Ship hull, golf club, tooth implant
Hard, similar strength to steel but lighter
High corrosion resistance

Question 4

Non ferrous O
Copper 1000C - think abt processes too
Zinc 400C
Silver 1000
Gold 1000
Tin 200

Answer 4

Copper - wire, pipes, PCB,
Ductile, malleable, tough,
Good thermal and electrical resistance
Can be soldered and brazed

Zinc - buckets, galvanising steel dustbins for protection, intricate die casting
Low melting point, good corrosion Res

Silver - jewellery, cutlery
Malleable, ductile, corrosion Res, can be soldered

Gold - jewellery, electric components
Same properties ^^

Tin - soft solder, food can coatings, rarely used in pure form
ductile, malleable
Low melting, corrosion res

Question 5

Ferrous
Low carbon steel 1500°C - 0.15-0.3% C
Medium carbon steel 1500 - 0.3-0.7%
Cast iron 1100 - 3.5%

Answer 5

Low carbon steel - nuts bolts washers, car bodies, outer panel for white goods
Ductile, malleable,
high tensile strength, low corrosion Res

Medium carbon steel - springs, garden tools
harder than lcs, but less ductile, malleable and tough

Cast iron - engine blocks, brakes, machine parts
Hard outer skin, brittle core
Good compressive strength

Question 6

Ferrous alloys

Stainless steel - 1500 - 18% Chrome,8% Nickel
Hss - 18% Tungsten, 4% Chromium, 1% Vanadium, 0.5-0.8% C
Die steel(tool steel)

Answer 6

Stainless steel - sinks, kitchenware, cutlery
Tough, hard, corrosion resistant

Hss - tool blades, drill bits, milling cutters etc
Hard, tough
high resistance to frictional heat

Die steel - blanking presses and
Hard tough

Question 7

Non ferrous alloy

Bronze 850-1000 - 90% Cu, 10% Tin - Process
Brass - 930 - 65% Cu, 35% Zn - Process
Duralumin - Al + 4% Cu, 1% Mg+Manganese
Pewter - 200

Answer 7

Bronze - coins, bearings
Tough, corrosion Res, can be cast

Brass - door furniture, cast taps and valves
Corrosion Res, good electric and thermal con, low melting, casts well

Duralumin - aircraft parts, vehicle parts
same strength as mild steel, but lighter, ductile, becomes harder as it works

Pewter - trophies, frames, decorative items
Malleable, low melting point, casts well