Summer Exams 2022 LC 5th Flashcards

1
Q

Explain term Synthetic Fibre

A

Chemically man-made fibre

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2
Q

Name 2 composite materials and their constiuents

A

Concrete (water, cement, aggregate)

Plywood (thin layers of wood glued together)

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3
Q

Explain ‘alloy’ and give an advantage

A

Mixture of 2 or more metals

It is stronger & more durable

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4
Q

Name the metals to produce following: Bronze & Solder

A

Bronze: Copper + Tin
Solder: Lead + Tin

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5
Q

Describe ‘resistance to impact’ as material property

A

The ability of a material to cope with shock load. It is a indicator of material toughness.

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6
Q

Outline an impact test to compare materials for the manufacture of bicycle helmets

A

Izod Impact Test

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7
Q

Briefly outline what is meant by Synthetic materials & Natural materials

A

Synthetic materials are chemically made by man-kind

Natural materials is made by plants or animals (naturally)

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8
Q

Complete missing information table:
Body Part: Seat
Material Classification: Fabric
Material: ?

A

Material: Polyester

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9
Q

Complete missing information table:
Body Part: Tyre
Material Classification: ?
Material: Steel-enforced rubber

A

Material Classification: Rubber

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10
Q

Complete missing information table:
Body Part: Headlight Lens
Material Classification: Ceramic
Material: ?

A

Material: Polycarbonate

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11
Q

Explain abbreviation: PET

A

Polyethylene Terephthalate

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12
Q

Outline 3 disadvantages of extensive use of PET bottles

A

Pollution
Not Biodegradable
Becomes Toxic in presence of Heat

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13
Q

Outline one way in which plastic bottles are designed to maximise their strength

A

Use a strong a material like PET

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14
Q

Explain with examples, each of following:
Mass Production
Batch Production

A

Mass Production: Produced in large quantities, usually by machinery. Example: plastic bottles
Batch Production: Producing many identical products simultaneously. Example: clothes

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15
Q

Differentiate between following forces:
Tension
Torsion
Compression

A

Tension: stretching of material
Torsion: twisting of material
Compression: squeezing/pushing of material

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16
Q

Describe with examples, how metal alloys and manufactured boards can increase the strength of the final material

A

Metal alloys improve the hardness of material while manufactured boards increases its strength

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17
Q

Explain abbreviation: CNC

A

Computerized Numerical Control

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18
Q

Outline 2 reasons why CNC is used in manufacturing of products

A

They’re cost effective

Reduces errors in manufacturing process

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19
Q

Describe what is meant by smart material

A

Smart materials are materials that are manipulated to respond in a controllable and reversible way

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20
Q

Suggest 2 uses of electrochromic glass in every day life

A

Skylights

Classroom settings

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21
Q

Discuss why it is important to consider how a product is disposed of once it reaches its end-of-life

A

Depending on the product, its material or any substances it contains must go to an appropriate place as it can be toxic or bring about harm

22
Q

Briefly outline two options available when disposing of a product such as a dog wheelchair

A

Incineration
Scrap
Landfills

23
Q

Describe what is meant by ‘veneer’ when referring to materials

A

A thin slice of more expensive woods that is often applied to manufactured boards to improve appearance and give an impression of high cost

24
Q

Briefly outline 2 reasons why manufactured boards are often used instead of solid wood in furniture production

A

Cheap

Come in big sheets

25
Q

Outline 3 properties of Plywood that make it a suitable material for manufacturing of hoverboard or skateboard decks

A
Strength of material 
Can be bent to shape
Cuts to shape easily
Finishes well
Flexible
26
Q

Describe a simple material test which could be used to determine if a given material is suitable for use in skateboard wheels

A

Load a material test sample against a rotating wheel and then deposit sand of controlled grit size, composition and flow rate between them

27
Q

Select a suitable material for the anti slip surface on the pedal pads. Justify your answer.

A

Rubber

It is a reasonably soft material that wears well giving good grip.

28
Q

Suggest 2 alternatives materials for takeaway coffee cups which can be recycled or will biodegrade

A

Paper
Cardboard
Glass
PLA-lined cups

29
Q

Describe two advantages of incineration as a method of disposing of expanded polystyrene

A

Saves sending to landfill

Waste disposal for long life material

Acts as a fuel in for incineration

30
Q

State 2 reasons for using steel tubing in the construction of racing cars

A

Tubing reduces weight

Reasonably cost effective

High strength-to-weight ratio

31
Q

Outline some benefits to consumers & environment of increasing use of electric cars

A

Expect reduced running costs
Cleaner air
Less noise pollution
Less burning of fossil fuels

Smoother & quieter driving experience

32
Q

Outline with examples, 2 advantages of using composite materials

A

A composite material is a combination of 2 or more chemically distinct materials with improved properties

  1. Plastic laminates provide a waterproof layer on chipboard for kitchen counters
  2. GRP is lightweight and strong
33
Q

Suggest 2 reasons for extensive use of glass in manufacture of Luas trams

A

Visibility for passengers
Security of passengers
Light weight

34
Q

Describe main properties of Thermosetting plastics. Give example(s).

A

Thermosetting can be set only once. They’re hard and have high melting point.
Example: Bakelite

35
Q

Describe main properties of Ferrous Metals. Give example(s)

A

Ferrous metal contain iron. Example: Steels are magnetic, malleable and ductile

36
Q

Describe main properties of Softwoods. Give example(s)

A

Softwoods are evergreen, soft and mature quickly

Example: pine

37
Q

Outline 2 potential hazards when using adhesives to bond materials

A

Adhesives can produce dangerous fumes, ventilation is needed

Care must be taken to not bond skin. Suitable adhesive must be selected to ensure good adhesion.

38
Q

Describe key features of following materials & give example(s): Thermoplastics

A

Will mold more than once, recyclable.

Example: Polyethylene & PVC

39
Q

Describe key features of following materials & give example(s):
Smart materials

A

Materials that respond to an external input

Example: memory wire, polymorph

40
Q

Describe key features of following materials & give example(s):
Manufactured boards

A

Wooden products generally produced from by-products of cutting timber
Example: Plywood, MDF

41
Q

Outline main safety hazards on following processing techniques:
Cutting MDF on a circular saw

A

Generation of dust
Fine particles
Need for extraction

42
Q

Outline main safety hazards on following processing techniques:
Joining plastic materials using adhesives

A

Fumes from solvent adhesives

Flammability

43
Q

Outline main safety hazards on following processing techniques:
Cutting metal on centre lathe

A

Sharp
Hot metal chips
Need eye protection

44
Q

Select an impact-resistant material for the door wedge. Justify your answer.

A

Polypropylene - can be injection moulded
Resistant to impact
Colorful

45
Q

Discuss the environmental impact of producing the toy car using vacuum forming techniques

A

Production of plastic materials from oil: extraction, energy use, transport etc

Electrical energy used in process

Recyclable plastic material

46
Q

Describe with the aid of detailed sketches, the process of vacuum forming?

A

This method is used to produce hollow shapes in plastic sheets. A shaped mould is produced, usually in wood, and placed in the machine. The sheet of plastic is placed over the mould & clamped. The sheet of plastic is heated until soft and drawn onto the mould. Vacuum created -> air removed from area of mould. The plastic sheet will take shape of the mould.

(machine turned off, mould removed and trimmed)

Practice drawing it yourself!

47
Q

Describe with the aid of detailed sketches, the process of injection moulding?

A

Practice drawing it yourself!

48
Q

Describe with the aid of detailed sketches, the process of extrusion moulding?

A

Practice drawing it yourself!

49
Q

Describe, using annotated sketches, a suitable production method for the plastic housing

A

Injection moulding: plastic pellets are loaded from the hopper through the heated chamber. It is pushed into the housing shaped mould by the rotating screw

ALSO PROVIDE A SKETCH!

50
Q

Explain, using annotated sketches, the process of vacuum forming

A

This method is used to produce hollow shapes in plastic sheets. A shaped mould is produced, usually in wood, and placed in the machine. The sheet of plastic is placed over the mould & clamped. The sheet of plastic is heated until soft and drawn onto the mould. Vacuum created -> air removed from area of mould. The plastic sheet will take shape of the mould.

(machine turned off, mould removed and trimmed)

Practice drawing it yourself!

51
Q

Describe, using annotated sketches a method of commercially manufacturing the front cover of this device.

A

Injection moulding: A hollow split mould is machined to the shape of casing. Plastic granules are held in hopper and fed into machine where heated and pushed into the mould cavity by screw/ram mechanism. The molten plastic fills the mould under heat and pressure. It sets quickly.

(Mould is split -> casings removed -> trimmed)

Practice drawing it yourself!