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Product design > Technical principles > Flashcards

Technical principles Flashcards

1
Q

Spruce properties/ performance characteristics and uses

A

Straight grain, resistant to splitting.

indoor furniture

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2
Q

Epoxy resin properties/ performance characteristics and uses

A

Rigid, clear, hard, tough, chemical resistant. Safe working temperature 80-200 °C.

Adhesives, surface coatings, encapsulation of electrical components, cardiac pacemakers, aerospace applications

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3
Q

Glass reinforced plastic (GRP) composite and properties and uses

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

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4
Q

Workshop tensile test

A

Tensile testing is done by placing a weight on a length of material that is held in a clamp or vice. The weight is applied to the end of the material, which sticks out from the vice. Tension will be applied to the top of the material with compression at the bottom.

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5
Q

Plywood properties/ performance characteristics and uses

A

Thin layers of wood are placed and glued at 90 degrees to one another and compressed to form the board. Good strength in all directions, no grain weakness, always has an odd number of layers.

Structural work, desktops, indoor furniture, floorboards

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6
Q

Workshop thermal test

A

thermometer which is placed a set distance from one end of the material. A Bunsen burner is lit under the end of the material for a set time. The shorter the time for the thermometer to reach a set temperature, the higher the thermal conductivity.

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7
Q

Rough sawn stock form

A

The wood comes directly from seasoning and has rough surfaces produced during initial conversion.
* Rough-sawn wood will have innacurate sizes rather than accurate finished sizes and is the cheapest stock form to buy.

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8
Q

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

Watercolour painting

A

Water colour paper

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9
Q

Cement poweder, sand, aggregate particles mixed with water

High compression strengh, low tensile strength, few surface defects, easy to mold

Pathways, beams, blocks, driveways, house of foundations

A

Concrete

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10
Q

Thin copper wire coated in a phosphorescent material that glows
in response to an alternating current

Glow bracelets, interweaving for clothing, home decoration, outdoor decorative lighting

A

Electroluminescent wire

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11
Q

Examples of manufactured boards

A

plywood, marine plywood, aeroplay, flexible plywood, chipboard, mdf

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12
Q

difference between steam bending and lamination

A

Steam bending is quicker than laminating and less wasteful. Laminating involves waiting for glue to dry and usually parts need to be trimmed to final size

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13
Q

What is an alloy and types

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 sub classified as ferrous alloys or non-ferrous alloys.

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14
Q

Polyurethane closed-cell foam blocks or sheets. Lightweight, easy to work using traditional woodworking tools, CNC miller/router, sands easily to allow intricate shapes and forms to be created.

3D modelling, prototypes

A

High-density modelling
foam

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15
Q

UV light stabilisers reason to add it and uses

A

Prevent the polymer chains being broken down by sunlight

Used in outdoor toys and play equipment, garden furniture, sport stadium seat and synthetic grass playing surfaces

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16
Q

Wrought iron forging -process type, process diagram, stock form, products, key features

A

metal forming

involving the shaping of metal using localized compressive forces using heat and hammer on an anvil

Bar

Decorative metalwork such as gate scrolls, decorative fencing

Uses wrought iron (carbon content less than 0.08%).
* Can be hand or hydraulic press process.
* Suitable for one-off or small-batch
production.

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17
Q

What are the wood enhancement methods

A

Resins, resin with fire retardants, laminations, preservatives, oigments, fire retardant, preservatives, modified natural polysaccharide, SCL and LVL

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18
Q

What can papers and boards be described as

A

They can be described as compliant materials meaning they can be scored folded and cut with basic materials

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19
Q

Corn starch polymer type, source and uses

A

Bio-polymer (natural). Made from high-starch vegetables such as corn, potatoes and maize.

Packaging products, straws, vending cups, disposable cutlery, bags, takeaway food containers

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20
Q

Granules that become mouldable at about 60 °C. 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 2°C

Modelling, shaping ergonomic handles, prototype mechanical parts

A

Polymorph

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21
Q

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

A

Plastazote

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22
Q

High tensile strength, low elongation, good hardness, tough, electrical insulator, good cold resistance.

Automotive industry such as tyres, tubes, hoses, gaskets, belts; balloons, toys, footwear

A

Natural rubber (polyisoprenel)

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23
Q

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

Gift boxes and packaging, high- quality metal effect business cards

A

Metal effect card

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24
Q

Acrylonitrile butadiene styrene (ABS) properties/ performance characteristics and uses

A

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

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25
Q

Tough, close grained, hard, available in steamed (white colour) and un-steamed (pink tinge).

Chairs, chopping boards, tools (mallet), steam bent laminated furniture, turned bowls

A

Beech

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26
Q

High-density modelling
foam features and uses

A

Polyurethane closed-cell foam blocks or sheets. Lightweight, easy to work using traditional woodworking tools, CNC miller/router, sands easily to allow intricate shapes and forms to be created.

3D modelling, prototypes

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27
Q

Sand casting- process type, process diagram, stock form, products, key features

A

Prepare the Mould: Sand mixed with a bonding agent is packed into a flask to create the mould cavity.
Add the Pattern: A pattern is placed in the sand to shape the mould cavity.
Remove the Pattern: The pattern is carefully removed, leaving a hollow cavity in the sand.
Pour the Molten Metal: Molten metal is poured into the mould cavity through a runner.
Cool the Casting: The metal is left to solidify and cool within the mould.
Break the Mould: The sand mould is broken apart to remove the solid metal casting.

Redistribution

Molten metal from a billet

Railway carriage wheels, wood working clamps, vices, motor housings, bollards, drain covers, post boxes

  • Labour-intensive process. not a high- quality surface finish.
  • suitable for one-off or small-batch production.
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28
Q

Bio-polymer (synthetic). Fully compostable. PLA and cellulose based.

Food film, bags, packaging wrap, bin bags, agricultural ground sheet, flower wrap

A

Glycolide (Lactel and Ecofilm)

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29
Q

What are the types of polymers

A

thermoforming, thermosetting and elastomer

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30
Q

are woods toxic and how come

A

can cause respiroty irritation and hardwood dusts are listed are carcinogenic both softwoods and hardwoods dust have workplace exposure limits of 5mg cubic metre

employers should have ventilation systems and mask

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31
Q

Rigid, clear, hard, tough, chemical resistant. Safe working temperature 80-200 °C.

Adhesives, surface coatings, encapsulation of electrical components, cardiac pacemakers, aerospace applications

A

Epoxy resin

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32
Q

What is a thermoforming polymer

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 Waals forces.

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33
Q

What is an electrical conductor

A

A material that allows the flow of electrical current ( good conductors have low resistance)

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34
Q

Drop forging process type, process diagram, stock form, products, key features

A

Drop Forging is a forging process where a hammer is raised and then ‘dropped’ onto the work piece to deform it according to the shape of the die.

Forming

billet

spanners, pliers and screwdriver shafts

Used for products that
need to be tough and hard.
* Maintains the internal grain
structure which retains the strength.
* Hot metal billet shaped on an anvil or die and then pressed into shape and cooled.
* Suitable for mass production.

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35
Q

Biopol (bio-batch additive) type and source and uses

A

Bio-polymer (natural). Made from bacteria grown in cultures. Additive to promote degradation. Usually 1% added to thermoplastics.

Packaging products such as film, carrier bags, vending cups, nappies, surgical stitches, pill coverings

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36
Q

all papers and boards

A

Layout paper, cartridge paper, tracing paper, bleed proof paper, treated paper, watercolour paper,
corrugated card, bleached card, mount board, duplex card, foil backed and laminated card, metal effect card, moulded paper pulp

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37
Q

What are materials classified by

A

Metals, woods, polymers, papers and boards, composites, smart materials and modern materials

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38
Q

Straight grain, resistant to splitting.

indoor furniture

A

Spurce

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39
Q

What is an elastomer polymer

A

a material which at room temperature can
be deformed under pressure and then upon release of the pressure, wil return to its original shape.
Elastomers have weak bonds which allow them to
stretch easily. They can be stretched repeatedly and
upon immediate release of the stretch, will return with force to the original length

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40
Q

all manufactured boards

A

Plywood, marine plywood, aeroply, flexible plywood,
chipboard, MDF

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41
Q

Blow moulding diagram, Polymer stock form, Products, Key features

A

Polymer is fed into the hopper
The polymer is heated and moved along using a screw Molten polymer is extruded as a tube called a ‘parison’ The mould closes around the parison and air is injected in forcing the polymer to the sides of the mould The polymer is cooled, the mould opens and the finish product is ejected.

Thermoplastic tube “parison’

Drinks bottles, shampoo bottles, detergent bottles, etc.

  • Produces hollow thin-walled components.
  • High initial tooling cost.
  • Used for continuous production.
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42
Q

Polyhydroxyalkanoate
(PHA) type and source and uses

A

Bio-polymer (natural). Made from bacteria grown in cultures. Fully compostable.

Packaging, medical uses such as slow-release medication patches, films, screws and bone plates

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43
Q

Fluted PP sheet properties/ performance haracteristics and uses

A

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

Signs (such as construction site signs,
sale boards for estate agents), storage box construction, portfolio cases, small models

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44
Q

what is material enhancement

A

its a way of improving a material’s properties to better suit the requirements of the final product.

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45
Q

Treated paper Properties/performance characteristics and uses

A

Plain paper with a clear binder or dye layer applied to help hold the image on the paper surface.

Photographic printing

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46
Q

Pigments in wood uses

A

Added to the preservative to give different coloured shades to enhance the aesthetics, e.g. outdoor decking.
Can also be used on cheaper softwoods to make them look like hardwoods.

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47
Q

Mahogany properties/ performance characteristics and uses

A

Can contain interlocking grain making it more difficult to work rich :dark red color

indoor furniture shop fittings and cabinets veneers commonly used on manufactured boards

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48
Q

What are wood manufacturing processes grouped into

A

addition forming and wasting processes

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49
Q

Made from compressed fine cotton fibres to produce a rigid board

Presenting artwork, picture mounting, modelling

A

Mount board

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50
Q

Rotational moulding diagram, Polymer stock form, Products, Key features

A

Involves a heated hollow mould which is filled with a charge or set weight of material. It is then slowly rotated, causing the softened material to disperse and stick to the walls of the mould. In order to maintain even thickness throughout the part, the mould continues to rotate at all times during the heating phase and to avoid sagging or deformation also during the cooling phase.

Thermoplastic powder or granules

Traffic cones, kayaks,
water tanks, kerosene tanks,
children’s play equipment

Seamless hollow components with a large wall thickness.
* Mould continuously rotated through
heating and cooling.
* Large-scale batch or mass production.

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51
Q

Die steel properties/ performance characteristics and uses

A

Hard tough

Blanking punches and dies,
extruder dies, fine press tools

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52
Q

Degradation due to oxygen (oxy-degradable)

A

polymer turns into a fine powder with exposure to oxygen and is subsequently degraded by the action of micro-organisms

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53
Q

characteristics of biodegradable polymers

A

Biodegradable polymers can produce methane gas when they decompose in landfills. Methane gas is a greenhouse gas that contributes to global warming.

Biodegradable polymers can take high temperatures to decompose and may leave behind toxic residues.

Do not necessarily encourage a sustainable or recyclable culture.

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54
Q

What are mechanical properties and name them?

A

how a material reacts to an external force. 11

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55
Q

Card with polymer film or foil applied to provide a water-resistant and/or heat-insulating layer.

Drinks packaging, milk cartons, take-away box lids

A

Foil-backed and laminated card

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56
Q

What are the additives added to enhance polymers

A

Lubricant, Thermal antioxidants, Pigments, Antistatics, Flame retardants, Plasticisers, Fillers, Biodegradable Plasticisers, Bio-batch additives , Antioxidants, UV light stabilisers

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57
Q

Mount board Properties/performance characteristics and uses

A

Made from compressed fine cotton fibres to produce a rigid board

Presenting artwork, picture mounting, modelling

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58
Q

Bio-polymer (natural). Made from bacteria grown in cultures. Additive to promote degradation. Usually 1% added to thermoplastics.

Packaging products such as film, carrier bags, vending cups, nappies, surgical stitches, pill coverings

A

Biopol (bio-batch additive)

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59
Q

Available in translucent, tough, flexible,good weathering resistance, goodchemical resistance. Safe working temperature 95 °C.

Hose pipes, cable insulation, medical grade tubing, inflatable products, imitation leather, seat coverings

A

Flexible polyvinyl chloride (PVC)

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60
Q

Ductile, high tensile strength, tough, malleable, poor resistance to corrosion 0.15%-0.3% carbon content melting temperature at 1427

nuts, bolts, washers, screws, car bodies, outer panels for white goods

A

Low carbon steel

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61
Q

Press forming -process type, process diagram, stock form, products, key features

A

the metal is placed inside the die. The press then applies high pressure (3000 tons of force or higher on large presses) and the material is formed to match the shape of the die. In other words, press forming is a forming technology where a pressing force is applied to a material to deform it (by bending, stretching, etc.) to match the size and shape of the die

Forming

Sheet

Metal seats, car body panels, boxes and containers

  • Shapes sheet metal into 3D
    forms.
  • Often used in conjunction with robots for lifting the sheet into
    place.
  • Suitable for mass production or large- scale batch production.
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62
Q

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

A

Glass reinforced plastic (GRP)

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63
Q

What is the industrial thermal conductivity test

A

using a heat flow meter, a square-shaped material test piece is placed between two temperature -controlled plates. The temperature is increased at a controlled rate and the heat flow through the material is measured.

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64
Q

Antistatics reason to add it

A

Reduce the likelihood of the polymer building up a static charge.

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65
Q

all softwoods

A

Pine, spruce, Douglas fir, redwood, cedar, larch

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66
Q

What is a thermal insulator

A

A material that doesn’t allow the transfer of heat energy

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67
Q

PAR stock form

A

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

The PAR board is about 3 mm smaller all round than the original rough- sawn nominal size and is the most expensive stock form to buy.

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68
Q

Metal effect card Properties/performance characteristics and uses

A

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

Gift boxes and packaging, high- quality metal effect business cards

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69
Q

What is density

A

The mass of the material

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70
Q

Preservatives uses wood

A

Protect wood (especially for outdoor use) from fungal and insect attack.
Wood can be pre-treated with a copper-based preservative, which penetrates the wood to protect the whole plank.

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71
Q

Cupping and deep drawing -process type, process diagram, stock form, products, key features

A

Cupping involves pressing a flat metal sheet (blank) into a shallow cup shape using a punch and die. Deep drawing extends this process, pulling the cup deeper into the die to create hollow, cylindrical shapes without fracturing the material.

Forming

Sheet

Tube-like shapes such as fire extinguishers, aerosol cans, drink cans

  • Starts with a metal blank.
  • Metal is stretched into shape.
  • High initial tooling cost.
  • Used for large- scale mass or continious production.
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72
Q

Changes colour with light intensity.

Welding goggles, reactive spectacle
lenses, security markers that show up under UV light

A

Photochromic pigment

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73
Q

Fibre cement composite and properties and uses

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 in freeze/thaw
situations.

Suspended floors, complex geometric shapes, pathways

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74
Q

Concrete composite and properties and uses

A

Cement poweder, sand, aggregate particles mixed with water

High compression strengh, low tensile strength, few surface defects, easy to mold

Pathways, beams, blocks, driveways, house of foundations

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75
Q

What are all the polymer enhancement

A

Lubricants
Thermal antioxidants
Pigments
Antistatics
Flame retardants
Plasticisers
Fillers
Biodegradable plasticisers
Bio-batch additives
Antioxidants
UV light stabilisers

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76
Q

Cartridge paper Properties/performance ,stics and uses

A

Off-white paper, usually with a slightly textured surface.

Sketching, rendering in pencil ink and pastel

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77
Q

Hard, similar strength to steels but more lightweight, high resistance to corrosion. Melting temperature 1668 °C.

Hip replacements, joint replacements, tooth implants,
spectacle frames, aircraft, spacecraft, golf clubs, bicycles, ship hulls

A

titanium

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78
Q

cast iron properties/ performance characteristics and uses

A

Hard outer skin but brittle core, good under compression 3.5% carbon Melting temperature 1149°C

disc brakes, machine parts and engine blocks

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79
Q

Engineered wood eg (glulam - glued laminated timber)

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

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80
Q

Nylon properties/ performance characteristics and uses

A

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

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81
Q

Carbon fibres mixed with polyester 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, helmet, prosthetics

A

Carbon fiber reinforced plastic (CFRP)

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82
Q

Layout paper properties and uses

A

Thin translucent paper with smooth surface

sketching ,technical drawing and tracing

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83
Q

Wood chips compressed with a resin such as urea formaldehyde.

Often veneered or covered with polymer laminate, kitchen worktops and units, shelving and ‘flat pack’ furniture

A

Chipboard

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84
Q

Natural wood stock form

A

Natural wood comes from trees and is available only at the maximum width o f the tree.
* To produce a wide desktop, natural wood planks need to be joined together.
* Planks should be joined with the end grain going in opposite directions to minimise distortion.

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85
Q

Corrugated card Properties/performance characteristics

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 takeaway boxes

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86
Q

What is magnetism

A

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

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87
Q

Low carbon steel properties/ performance characteristics and uses

A

Ductile, high tensile strength, tough, malleable, poor resistance to corrosion 0.15%-0.3% carbon content melting temperature at 1427

nuts, bolts, washers, screws, car bodies, outer panels for white goods

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88
Q

Low-density polyethylene (LDPE) sheet properties/ performance haracteristics and uses

A

Tough, available in thin sheet
form. transparent good chemical resistance flexible

Food wrapping, air pillow packaging,
bubble wrap, carrier bags

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89
Q

A cermet (mixture of ceramic and metal particles) Ceramic tungsten and cobalt metal

Hard, tough, resistant to high temperatures, corrosion resistant

Cutting tools such as drill bits router bits kitchen knifes

A

Tungsten carbide

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90
Q

Harder than, low-carbon steel but less ductile, malleable and tough 0.30-0.70% carbon content.
1425-1540 melting temperature

springs, gardening tools

A

medium carbon steel

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91
Q

What are the industrial tests for hardness

A

In the Rockwell test a preload weight is applied to the material sample using a diamond indenter which just breaks through the surface. An additional load is then applied to the test material and held for a predetermined length of time. The distance between the preload and applied load is then measured.

The Brinell test uses a standard sized steel ball which is forced into the materials surface using a pre-set load. The diameter of the indent is measured. The smaller the indent, the harder the material.

Vickers pyramid test is used for very hard materials and uses a diamond square-based pyramid to indent the surface of the material. Diamond is used as it will not 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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92
Q

Zinc properties/ performance characteristics and uses

A

Low melting point, good corrosion resistance.
Melting temperature 420 °C.

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

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93
Q

Lightweight, ductile, malleable, corrosion resistant, electrical and thermal conductor, can be metal inert gas (MIG) and tungsten inert gas (TIG) heat welded.
Melting temperature 660 °C.

Drinks cans, aircraft bodies, bike frames, window frames, saucepans, cooking utensils, packaging, baking foil

A

Aluminium

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94
Q

Marine plywood properties/ performance characteristics and uses

A

Similar construction to plywood but is gap and void free, and uses specialist water and boil-proof (WBP) glue to provide resistance to moisture. Some higher-quality marine plywood is also resistant to fungal attack.

Boat dashboards, boat lockers and panelling

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95
Q

changes colour in response to temperature change

Room thermometers, medical
thermometers for children, bath water thermometers, colour change mugs and kettles, food packaging to indicate food is hot to eat or cool for drinks, baby feeding spoons, battery charge indicator strips

A

Thermochromic
pigment

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96
Q

Low melting point, good corrosion
resistance. Melting temperature 420 °C.

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

A

Zinc

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97
Q

All smart materials

A

Shape memory alloys (SMA), thermochromatic pigment,
thermochromatic film, phosphorescent pigment,
photochromic pigment, electroluminescent wire,
piezo electric material

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98
Q

What are key properties of Polymer sheet

A

thicker than polymer film and is available in stock sheets of varying thicknesses - for example, foam board sheet is available in 3 mm, 5 mm, 10 mm and 20 mm standard thickness.

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99
Q

Brass properties/ performance characteristics and uses

A

Corrosion resistant, good electrical
and thermal conductor, low melting
point 930°C, casts well.
65% copper, 35% zinc.
Melting temperature 930 °C.

Boat fittings, door furniture,
cast valves and taps, ornaments

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100
Q

High speed steel(HSS) properties/ performance characteristics and uses

A

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

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101
Q

Malleable, ductile, corrosion resistant, can be soldered. Melting temperature 1063 °C.

Jewellery, electronic components, connectors, switch components

A

Gold

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102
Q

Lactide type and source and uses

A

Bio-polymer (synthetic). Fully compostable, water soluble. PLA and cellulose based.

Biomedical applications, slow- release medication, bone repair fixings, detergent washing sachets

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103
Q

What is translucent

A

A material that allows light but diffuses the light making it blurry or cloudy

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104
Q

All elastomers

A

Natural rubber, polybutadiene, neoprene, silicone

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105
Q

Line bending diagram, Polymer stock form, Products, Key features

A

A process which involves heating up a small area of plastic sheet so it can be folded or bent like paper. Usually this is done around a former.

Thermoplastic sheet

Acrylic boxes, shelves or point-of-sale displays

Uses an electrically heated element
that provides heat along a line.
* Quite slow and labour-intensive, used in school or college workshops.
* Suitable for one-off or limited batch production.

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106
Q

What are the wasting processes

A

Milling, turning, flame cutting, plasma cutting, laser cutting and punching stamping

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107
Q

Hard, straight close grained, resists warping

Furniture indoor panelling veneers used for birch faced plywood constructions

A

Birch

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108
Q

Piezoelectric material how does it work and uses

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 barbecues, vibration damping in tennis racquets, musical greetings cards, pressure sensors

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109
Q

What is ductility

A

the ability to be drawn out under tension without cracking

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110
Q

Modified natural polysaccharide uses wood

A

Wood is impregnated to cure within the wood cell structure. Results in
increased hardness, toughness and stability (often added to hardwood floor panels).

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111
Q

Manufacture boards stock form

A

These are man-made and produced in large sheets,
typically 1220 mm x 2440 mm.
* Wide surfaces can be produced from one sheet without the need for joining processes.

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112
Q

All alloys

A

Ferrous alloys: stainless steel, die steel

non ferrous alloys- bronze, brazz, duralumin, pewter

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113
Q

What is a non-ferrous metal

A

A metal that does not contain iron.
Non-ferrous metals are not magnetic and do not rust.

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114
Q

What makes degradation occur and what does it depend on

A

Degradation occurs because of the action of micro-organisms, which convert the material into water, carbon dioxide (CO2), biomass and possibly methane (CH4)

The ability of a polymer to biodegrade is dependent on the structure of the polymer rather than the origin of the raw material.

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115
Q

Tracing paper Properties/performance characteristics and uses

A

Translucent paper, slightly thicker than layout paper.

Copying images when sketching

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116
Q

Natural rubber (polyisoprene) properties/ performance characteristics and uses

A

High tensile strength, low elongation, good hardness, tough, electrical insulator, good cold resistance.

Automotive industry such as tyres, tubes, hoses, gaskets, belts; balloons, toys, footwear

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117
Q

Laser cutting- Paper and board forming processes

A

Laser cuting(cnc) is ideal for prototype or small-scale production because it an be used to cut, engrave and perforate papers and boards It:

  • is faster than traditional methods
  • gives repeated accuracy
  • provides a high level of detail|
  • allows the design to be quickly edited and then manufactured.
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118
Q

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

Decorative laminates, picnic ware, buttons

A

Melamine formaldehyde (MF)

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119
Q

Bio-polymer (natural). Made from potato starch.

Single-use food items such as bowls, cutlery, food trays, serviettes, packaging beads or peanuts, bin bags

A

Potatopak

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120
Q

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, aerospace applications tubing for drug delivery systems

A

Silicone

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121
Q

Clay consistency material made up of fine metal particles. Works like ceramic clay, easily mouldable, easy to shape and form, sets hard once
fired with a kiln or butane torch.
Inexpensive compared to solid metals such as Silver.

Jewellery, decorative items, small
sculptures, fobs

A

Precious metal clay
(PMC)

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122
Q

Spinning- process type, process diagram, stock form, products, key features

A

is a process by which a disc of metal is rotated at high speed and formed into a symmetrical part. Metal spinning does not involve removal of material but forming of sheet material over an existing shape.

Forming

Sheet

Body of stainless steel kettles, saucepans, metal light shades

  • Product may show parallel lines where the sheet has been forced onto the mandrel
  • Suitable for mass production or small-batch production
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123
Q

Characteristics of polymers

A

The majority of polymers are made via the fractional distillation of crude oil, which is a non-renewable resource.

Synthetic polymers are made from crude oil and take hundreds of year to decade

Polymers are ‘self-finishing’ (can be pigmented during the manufacture process to give colour and therefore require no additional secondary finishing process).

Can be grouped as a thermoforming, thermosetting and elastomer polymer

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124
Q

Bio-batch additives reason to add it

A

Oxy-degradable photodegradable and hydro-degradable additives help reduce the degradation time from hundreds of years to a few years or even months.

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125
Q

Pewter properties/ performance characteristics and uses

A

Malleable, low melting point
170-230°C, casts well.
85-99% tin, with the remainder
consisting of copper and antimony.
Melting temperature 170-230 °C.

Tankards, flasks, goblets,
photo frames, decorative items,
candlesticks, sports trophies

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126
Q

Foil-backed and laminated card Properties/performance characteristics and uses

A

Card with polymer film or foil applied to provide a water-resistant and/or heat-insulating layer.

Drinks packaging, milk cartons, take-away box lids

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127
Q

Aeroply properties/ performance characteristics and uses

A

Plywood made from 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

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128
Q

Causes of degradation

A

light (photodegradable)

oxygen (oxy-degradable)

water (hydro-degradable)

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129
Q

Celulose acetate properties/ performance characteristics and uses

A

Transparent, tough, naturally biodegrades.

Packaging film, membranes, photographic films

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130
Q

Photochromic pigment how does it work and uses

A

Changes colour with light intensity.

Welding goggles, reactive spectacle
lenses, security markers that show up under UV light

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131
Q

workshop hardness test types and how they are done

A

Abrasive wear can be easily tested by running a file over the surface of the material. The material with the fewest scratches is the hardest.

A dot punch can be placed on the material and hit with a hammer. The larger the surface indentation, the softer the material. Again, maintaining the same force for each blow is difficult and can lead to inconsistent results.

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132
Q

Laser cutting

A

This process can be used in industry for precision cutting metals. Lower-powered lasers are readily available in schools and colleges to cut manufactured boards and acrylic sheet.
* Laser cutting uses the power from a high-powered laser beam that is directed through optics.
* The laser head contains a lens that focuses the laser into a fine beam for cutting and engraving.
* Laser beams usually have a very fine tolerance (can be less than 1 mm).
* Laser cutting is more accurate and uses less energy than plasma cutting but cannot cut to the same thickness of material.
* In industry, laser cutting is typically used to cut flat sheet material, but it is not able to cut to the same thickness as plasma cutting.

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133
Q

Workshop corrosion test

A

expose the material to environmental effects such as rain or sun. The material is simply placed outside in an area exposed to the elements. They can then be visually inspected for signs of surface corrosion.

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134
Q

Gold properties/ performance characteristics and uses

A

Malleable, ductile, corrosion resistant, can be soldered. Melting temperature 1063 °C.

Jewellery, electronic components, connectors,switch components

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135
Q

How do you make a test fair

A

same size material- environmental conditions the same- same equipment- same force- same person

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136
Q

Hard, heat resistant, good electrical insulator, brittle

Electrical fittings, adhesives

A

Urea formaldehyde (UF)

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137
Q

What are the different stock forms of wood

A

Rough-sawn, PSE, PAR, natural wood, manufactured boards and mouldings

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138
Q

What is a biodegradable polymer

A

a polymer that can be made from finite resources such as crude oil and contains additives that
cause it to degrade more quickly than traditional polymers.

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139
Q

What are MF laminates

A

Thin sheets of MF polymer hard tough chemical resistant used for decorative coverin

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140
Q

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

Signs (such as construction site signs,
sale boards for estate agents), storage box construction, portfolio cases, small models

A

Fluted PP sheet properties/ performance haracteristics and uses

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141
Q

Straight grain, knotty, can contain resinous knots.

Construction work, roof beams, and timber frames and interior joinery

A

Pine

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142
Q

corrision resistent, low meting point, Melting temperature 232 °C.

soft solder, coatings for food cans, rarly used in pure from

A

Tin

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143
Q

What are the polymer processes

A

Vacuum forming, thermoforming, calendering, line bending, lamination, injection moulding, blow moulding, rotational moulding, extrusion and compression moulding.

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144
Q

What is corrosion resistance

A

the ability of the material to withstand environmental decay

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145
Q

Polyester resin properties/ performance characteristics and uses

A

Rigid, heat resistant, chemical resistant, brittle. Safe working temperature 95 °C.

Castings, used in lay-up process for glass reinforced plastic (GRP) for boat hulls, car parts, chair seats

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146
Q

Workshop toughness test and a problem with it

A

Place the test material in a vice then hit it with a hammer. The more impact it can withstand, the tougher the material. Brittle materials will withstand less force The problem with this test is maintaining a consistent level of force with each blow.

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147
Q

Larch properties/ performance characteristics and uses

A

Hard, tough, attractive grain pattern, fades to silver upon exposure outside

Garden furniture, cladding, decking and fencing

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148
Q

Oak properties/ performance characteristics and uses

A

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

Furniture, flooring, boat building, lading, interior and exterior joinery

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149
Q

What are the types of metals

A

Ferrous, non-ferrous and alloys

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150
Q

Rigid polyvinyl chloride
(uPVC) properties/ performance characteristics and uses

A

Rigid, opaque, tough, hard, good weathering resistance, good chemical resistance. Safe working temperature 95 °C.

Window frames, external doors, guttering and downpipes for buildings, water service pipes, bank
cards

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151
Q

What is a thermosetting polymer

A

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

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152
Q

Rigid, opaque, tough, hard, good weathering resistance, good chemical resistance. Safe working temperature 95 °C.

Window frames, external doors, guttering and downpipes for buildings, water service pipes, bank cards

A

Rigid polyvinyl chloride
(uPVC)

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153
Q

Polylactic acid (PLA) type and source and uses

A

Bio-polymer (synthetic) Made from 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

154
Q

Bio-polymer (natural). Made from bacteria grown in cultures. Fully compostable.

Packaging, medical uses such as slow-release medication patches, films, screws and bone plates

A

Polyhydroxyalkanoate (PHA)

155
Q

What are key properties of polymer film

A

usually very thin and flexible, such as celulose acetate used for photographic film.

156
Q

Pigments polymers reason to add it

A

Tiny particles that are mixed into the polymer in its molten state to give colour to the final processed product

157
Q

Moulded paper pulp Properties/performance characteristics and uses

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

158
Q

Tempering- metal enhancement

A

A heat treatment reduces some of the excess hardness and brittleness of a hardened metal, and increases the toughness and ductility.

  • The metal is heated to below the critical point for a given time then
    slowly air cooled.
  • The exact temperature wil determine the amount of hardness removed.
  • Tempering colour on the metal indicates the temperature at which
    brittleness is removed.
159
Q

Water colour paper Properties/performance characteristics and uses

A

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

Watercolour painting

160
Q

Available in translucent form, weather proof, tough, good chemical resistance. Safe working temperature 65 °C.

A

High-density
polyethylene (HDPE)

161
Q

fire-retardant
preservatives uses for wood

A

Used to pressure treat wood for roof joists, cladding etc. and exhibition stands. Wood can also be treated to make it harder and more resistant in high-wear situations such as flooring.

162
Q

What are the key properties of paper and boards derived from their natural origin?

A

Original source of paper is wood pulp(grey)

During manufacture, bleaches are added to make paper white

The natural source makes paper and boards suitable for recycling they will biodegrade in landfills

163
Q

Biodegradable plasticisers reason to add it

A

These make the polymer more flexible, softer and easier to break down, which means faster degradation time.

164
Q

Examples of softwoods

A

pine, spruce, douglas fir, larch and cedar

165
Q

What is paper thickness measured in

A

gsm– grams per square metre

the lower the lighter the paper

166
Q

Why do we season woods

A

gives greater immunity from decay and increased resistance to rot
* increases strength and stability
* helps preservatives to penetrate
* makes wood less corrosive to metals.

167
Q

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 in freeze/thaw
situations.

Suspended floors, complex geometric shapes, pathways

A

Fibre cement

168
Q

What is Steam bending as a wood process

A

Combined heat and steam make strips of wood pliable so they can be shaped over a former.
* Wood is placed into a steam box where it wil absorb the steam.
* The wood is then bent over a former and clamped to it until it dries.

169
Q

Thin translucent paper with smooth surface

sketching ,technical drawing and tracing

A

Layout paper

170
Q

Aluminium sheets with a polyethylene core

Lightweight, rigid, tough, malleable, good thermal and sound insulation, good vibration damping.

Soundproofing panels in cars, buildings and boats

A

Aluminium composite board

171
Q

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

A

Acrylonitrile butadiene styrene (ABS)

172
Q

Bronze properties/ performance characteristics and uses

A

Tough, corrosion resistant, can be
cast.
90% copper, 10% tin.
Melting temperature 850-1000 °C

Statues, coins, bearings

173
Q

Bending- process type, process diagram, stock form, products, key features

A

When a sheet metal component is put on top of a die and pressure is dropped on the metal forcing it to fit the die

Forming

sheet or plate

Seams on metal edges, bending sheets for product casings or housings

Does not include any punching or
trimming of the metal.
* Simple bending can be carried out in a school or college workshop.
* Used for large- scale batches in industry.

174
Q

Equivalent strength properties to
mild steel but more light weight,
ductile, becomes harder as it is
worked. Aluminium with 4% copper, 1%
magnesium and manganese.

Aircraft parts, vehicle parts

A

Duralumin

175
Q

Hardening- metal enhancement

A

Medium and high carbon steels are heated to alter their crystalline
structure, holding them at this temperature for a given time and then quenching them in water, oil or salt-water baths. The hardening and subsequent quenching increase hardness but also increase brittleness.

176
Q

What is the industrial electrical conductivity test

A

a four-point probe method can be used to determine the electrical conductivity of materials. Four small diameter wires are stretched, parallel to each other, across a non-conductive polymer block. Ohm’s law can be used to calculate the resistance of the material sample.

177
Q

Can contain interlocking grain making it more difficult to work
rich dark red color

indoor furniture shop fittings and cabinets veneers commonly used on manufactured boards

A

Mahogany

178
Q

What is a modern material

A

A material developed through the invention of new or improved processes

179
Q

What is tensile strength

A

The ability to resist stretching or pulling forces

180
Q

What is a softwood

A

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

181
Q

Off-white paper, usually with a slightly textured surface.

Sketching, rendering in pencil ink and pastel

A

Cartridge paper

182
Q

smooth, bleed-proof, quick-drying, opaque, lightweight

Spirit-based marker rendering

A

Bleed-proof paper

183
Q

All hardwoods

A

Oak, ash, mahogany, teak, birch, beech

184
Q

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

A

Moulded paper pulp

185
Q

prosphorescent pigment how does it work and uses

A

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

Fire exit signs, ‘glow in the dark’ products such as adhesive stars, masks, night lights, watch hands

186
Q

Plastazote foam properties/ performance haracteristics and uses

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

187
Q

SMAs, e.g. nitinol how does it work and uses

A

Changes shape in response to a change in temperature or electrical input, e.g. nitinol wire in dental braces can change at body temperature when placed in the mouth to mantain constant tension and if heated to a certain temperature it will return to its original shape

Dental braces, self-closing windows, aeroplane wing flaps, bioengineering such as stents, bone plates and screws

188
Q

Aramid fibres with high cut- and heat-resistant properties.

Body armour, cut-proof gloves and
aprons, aerospace applications,
surfboard components, puncture resistant bicycle tyres

A

Kevlar

189
Q

What is the difference between modern and smart materials

A

Modern materials are not ‘smart materials’ because they do not react to external change.

190
Q

Malleable, ductile, corrosion resistant, can be soldered. Melting temperature 962 °C.

Jewellery, cutlery, used for plating other materials

A

Silver

191
Q

Vacuum forming process diagram, Polymer stock form, Products, Key features

A

involves heating up a sheet of plastic then raising a former or pattern up through the plastic while removing the air below to create a vacuum. This then causes atmospheric pressure outside the vacuum to ‘force’ the plastic down on to the former.

Thermoplastic sheet up to about 6 mm in thickness

Lightweight trays, box inserts and liners, takeaway coffee cups and yoghurt pots

  • Moulds are relatively easy to make but need a draft angle, air holes and
    rounded corners.
  • Not cost effective for one-off manufacture.
  • Small-scale batch and mass production.
192
Q

Stock form for papers

A

From A0 (largest) to A8 (smallest)

Each A is half the size of the previous A4 is half the size of A3

193
Q

Rigid, heat resistant, chemical resistant, brittle. Safe working temperature 95 °C.

Castings, used in lay-up process for glass reinforced plastic (GRP) for boat hulls, car parts, chair seats

A

Polyester resin

194
Q

Similar construction to plywood but is gap and void free, and uses specialist water and boil-proof (WBP) glue to provide resistance to moisture. Some higher-quality marine plywood is also resistant to fungal attack.

Boat dashboards, boat lockers and panelling

A

Marine plywood

195
Q

Polymorph features and uses

A

Granules that become mouldable at about 60 °C. 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 2°C

Modelling, shaping ergonomic
handles, prototype mechanical
parts

196
Q

What is fusibility

A

the ability of the material to be fused or converted from a solid to a liquid or a molten state by heat usually( essential for metal cast)

197
Q

Teak properties/ performance characteristics and uses

A

Hard, tough, straight grain, natural oils resist moisture, acids and alkalis.

Outdoor furniture laboratoy benches traditional boat decks

198
Q

Foam board properties/ performance haracteristics and uses

A

Two outer layers of card with a foam middle core

Mood board backing, presentation boards, modelling

199
Q

Silicone properties/ performance characteristics and uses

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, aerospace applications tubing for drug delivery systems

200
Q

Medium carbon steel properties/ performance characteristics and uses

A

Harder than, low-carbon steel but less ductile, malleable and tough 0.30-0.70% carbon content.
1425º-1540ºC melting temperature

springs, gardening tools

201
Q

Corrosion resistant, good electrical
and thermal conductor, low melting
point 930°C, casts well.
65% copper, 35% zinc.
Melting temperature 930 °C.

Boat fittings, door furniture,
cast valves and taps, ornaments

A

Brass

202
Q

titanium properties/ performance characteristics and uses

A

Hard, similar strength to steels but more lightweight, high resistance to corrosion. Melting temperature 1668 °C.

Hip replacements, joint replacements, tooth implants,
spectacle frames, aircraft, spacecraft, golf clubs, bicycles, ship hulls

203
Q

What is toughness

A

The ability to absorb impact force without fracture

204
Q

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

Wetsuits, laptop cases, industrial wire insulation, automotive applications such as shock absorber seals, hose covers, transmission belts, gaskets and door seals

A

Neoprene (polychloroprene
rubber)

205
Q

What is transparent

A

A material that allows light to pass through easily

206
Q

Hard outer skin but brittle core, good under compression 3.5% carbon Melting temperature 1149°C

disc brakes, machine parts and engine blocks

A

cast iron

207
Q

Low-density
polyethylene (LDPE) properties/ performance characteristics and uses

A

Very tough, good chemical resistance,
weather proof, available in translucent, low level of rigidity. Safe working temperature 65 °C.

Squeezy detergent bottles, toys,
carrier bags, bin liners, general
packaging, food wrap film, food
trays

208
Q

what is a simple workshop test

A

a test using basic tools and equipment

209
Q

Degradation due to water (hydro-degradable)

A

(hydro-degradable) - polymer quickly breaks down with exposure to water and is subsequently degraded by the action of micro-organisms

210
Q

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

A

Polypropylene (PP)

211
Q

Why is material testing used and what the most important thing when doing so

A

to select the most appropriate material for a product and make the tests fair

212
Q

What is a ferrous metal

A

A metal containing mostly iron and carbon.
Ferrous metals are magnetic and wil rust.

213
Q

PSE stock form

A

Wood has only one edge that is planed accurately; the rest are rough sawn Planing removes about 3 mm from the original nominal size.

214
Q

Aluminium properties/ performance characteristics and uses

A

Lightweight, ductile, malleable, corrosion resistant, electrical and thermal conductor, can be metal inert gas (MIG) and tungsten inert gas (TIG) heat welded. Melting temperature 660 °C.

Drinks cans, aircraft bodies, bike frames, window frames, saucepans, cooking utensils, packaging, baking foil

215
Q

Pressure die casting
(hot chamber) process type, process diagram, stock form, products, key features

A

Die casting is a process where molten metal is forced into a mould under high pressure. The mould is made from two strong steel dies that fit together to form the shape.

The molten metal is heated in the machine and a ram forces a SHOT of metal through the GOOSE NECK into the mould, it is very fast and the pressure will allow extra detail on the cast. Zinc, Tin, Lead

Hot-chamber machines: For metals like Zinc and Lead.

Redistribution

Molten metal from a billet

Toy cars, collectible figures, decorative door knobs and handles

  • Lower melt point metals such as aluminium, aluminium alloys and zinc-based alloys.
  • Molten metal stored in a chamber then a shot of molten metal is forced into the die.
  • fast process
    -used for ver large-batch and mass production
216
Q

What is elasticity

A

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

217
Q

Plain paper with a clear binder or dye layer applied to help hold the image on the paper surface.

Photographic printing

A

Treated paper

218
Q

Pine properties/ performance characteristics and uses

A

Straight grain, knotty, can contain resinous knots.

Construction work, roof beams, and timber frames and interior joinery

219
Q

Bio-polymer (natural). Made from high-starch vegetables such as corn, potatoes and maize.

Packaging products, straws, vending cups, disposable cutlery, bags, takeaway food containers

A

Corn starch polymer

220
Q

all Thermosetting polymers

A

Urea formaldehyde (UF), melamine formaldehyde (MF),
polyester resin, epoxy resin

221
Q

Polylactide properties/ performance characteristics and uses

A

transparent tough naturally biodegradable

Biodegradable packaging film

222
Q

What is plasticity

A

The ability to be permanently deformed and retain the deformed shape

223
Q

Bleed-proof paper Properties/performance characteristics and uses

A

Similar to cartridge paper but it is bleed-proof so
Spirit-based marker rendering
c o l o u r s do not r u n .

224
Q

Case hardening purpose and process- metal enhancement

A

Case hardening is used for hardening the surface of steels with less than
0.4 per cent carbon content.

  • Case hardening produces an outer casing of greater hardness, improved
    wear resistance and resistance to surface indentation, while the inner
    core of the metal retains the original ‘softer’ properties.
  • Case hardening is a two-stage process:

1) Carburising: this changes the chemical composition of the surface of low carbon steel so that it can absorb more carbon to increase surface hardness.

  • In industry, the steel is placed in a ceramic box that is packed with
    carbon. The box is heated to about 930-950°C, the carbon atoms
    diffuse into the material’s structure to build up the surface carbon
    content.
  • The depth of the carbon layer is determined by the length of time
    the material is exposed to carbon.
  • The longer the time, the thicker the carbon layer. The product is
    then heated to about 760°C and then quenched.

2) Quenching: the hot metal is quenched in water to fast-cool it and seal the hard surface case while not affecting the properties of the inner
core.

225
Q

Laminations uses wood

A

Veneers such as natural wood are laminated on to the board surface to enhance aesthetics

226
Q

Punching /stamping

A

This process uses computer-controlled machines that stamp out sections of sheet material.
* It uses the shearing action on a sheet of metal placed between an upper tool (punch) and a lower tool (die).
* The process is suitable for small- and medium-size production runs, and it is normally used for processing metals from 0.5 mm to 6 mm thickness.

227
Q

Urea formaldehyde (UF) properties/ performance characteristics and uses

A

Hard, heat resistant, good electrical insulator, brittle

Electrical fittings, adhesives

228
Q

Air seasoning

A

is traditional and inexpensive.
* Wood is stacked in a shelter outside, protected from the rain.
* Air circulates between the planks to remove excess moisture.
* It is a slow process, taking up to one year.
* The wood is used for outdoor products.

229
Q

Bio-polymer (synthetic) Made from 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

A

Polylactic acid (PLA)

230
Q

What are the stock forms of metals

A

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

  • Plate is generally thicker than 3 mm and narrower than sheet metals.
  • Bar is solid form, flat bar, square bar, round bar or hexagonal bar.
  • Tube form is hollow in cross-section and can be square, rectangular
    (also caled box section), round or hexagonal.
  • Structural angular shapes such as H beams, L beams (angle), I beams,
    tee bar and channel.
231
Q

SMA and transition temperature

A

When Smas are heated to a certain temperature( transition temperature) it will return to its original shape

232
Q

Copper properties/ performance characteristics and uses

A

Ductile, malleable, tough, corrosion resistant, good electrical and thermal conductor, can be soldered
and brazed. Melting temperature 1083 °C.

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

233
Q

What are the metal processes

A

Press forming, spinning, cupping and deep drawing, drop forging, wrought iron forging, bending, rolling, sand casting, gravity die casting, pressure die casting (hot chamber), pressure die casting (cold chamber) investment casting and low temperature pewter casting

234
Q

Flame retardants reason to add it

A

Reduce the likelihood of combustion or the spread of fire (car engine components) or potential electrical fires such as plug sockets.

235
Q

What is malleability

A

The ability to withstand deformation by compression without cracking( malleability increases with temperature)

236
Q

What are physical properties and name them

A

The actual make-up or structure of the material. 4

237
Q

Precious metal clay
(PMC) features and uses

A

Clay consistency material made up of fine metal particles. Works like ceramic clay, easily mouldable, easy to shape and form, sets hard once
fired with a kiln or butane torch.
Inexpensive compared to solid metals such as Silver.

Jewellery, decorative items, small
sculptures, fobs

238
Q

What is shear strength

A

The ability to resist sliding forces on a parallel plane

239
Q

Polypropylene (PP) properties/ performance characteristics and uses

A

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

240
Q

Degradation due to light (photodegradable)

A

polymer bonds are weakened and the polymer breaks down with exposure to ultraviolet (UV) light, such as UV rays from sunlight

241
Q

Compression moulding diagram, Polymer stock form, Products, Key features

A

Material is preheated and placed in a heated mould Mould is closed under pressure from the top plug The pressure pushes the polymer( like granules)into all areas of the mould Heat and pressure maintained until the polymer fits the mould

Thermoset polymer charge

Electrical light fittings, switches,
plugs, picnic plates and cups

Uses a pre- weighed ‘slug’ of
polymer.
* Polymer removed from moulds while still warm.
* Large-scale batch production.

242
Q

Cement powder, sand, aggregate particles and low carbon steel rods (rebar) mixed with water

High compression and tensile strength, consistency across the structure, few surface defects, fire resistant

Buildings, bridge piles and bridge spans, retaining walls, grid floors

A

Reinforced concrete

243
Q

High-impact polystyrene
(HIPS) properties/ performance characteristics and uses

A

Hard, rigid, available in translucent, tough. Safe working temperature 70 °C.

Yoghurt pots, refrigerator linings, single-use drink cups, toilet seats, instrument control knobs

244
Q

What is opaque

A

A material that doesn’t allow light to travel through

245
Q

All modern materials

A

Kevlar, precious metal clay (PMC), high density
modelling foam, polymorph

246
Q

Chipboard properties/ performance characteristics and uses

A

Wood chips compressed with a resinn such as urea formaldehyde.

Often veneered or covered with polymer laminate, kitchen worktops and units, shelving and ‘flat pack’ furniture

247
Q

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 barbecues, vibration damping in tennis racquets, musical greetings cards, pressure sensors

A

Piezoelectric material

248
Q

Milling wood process

A

Milling is used for small-sized, basic jobs such as a rough prototype or
roughing out a small hole or channel.
* Slow process and miling machines do not have as large a work area as
computer numerically controlled (CNC) routers.
* They can be operated manually or they can be CNC.

249
Q

MDF is compressed wood fibres, 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 or mould making, furniture items such as bookcases, cabinets and desks

A

MDF

250
Q

What is the industrial test for toughness

A

Izod impact test: a notched piece of material is held vertically in the vice of the machine. A pendulum is released from a set position. The energy absorbed is calculated from the height the pendulum swings to after it hits the piece. The material that absorbs the most impact is the toughest.

251
Q

Cedar properties/ performance characteristics and uses

A

Straight grain, can corrode ferrous metals due to acidic nature, low density, good sound damping rot and insect resistant

Exterior cladding, sheds, greenhouses, beehives, interior panelling

252
Q

Kevlar features and uses

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

253
Q

What is a compliant material

A

Materials that can be scored folded and cut with basic tools to form stuff like nets for packaging

254
Q

Polymethylmethacrylate (PMMA) properties/ performance characteristics and uses

A

Tough, hard, good chemical resistance, available in translucent. Safe working temperature 95 °C.

Car light casings, computer numerically controlled (CNC) laser- cut items, lighting units, lighting covers,bath

255
Q

Routering wood processes

A

Routering is used to machine slots and holes in wood, or to make
decorative ‘mouldings’ on the edges, for example on a table top.
* Can be manual plunge routers or computer numerically controlled (CNC).

256
Q

What is bending strength

A

The ability to resist forces that may bend the material

257
Q

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

A

High speed steel( HSS)

258
Q

What are veneers

A

Thin slices of wod less than 3 m used for Decorative coverings for manufactured boards

259
Q

What is a hardwood

A

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

260
Q

Tough, corrosion resistant, can be
cast.
90% copper, 10% tin.
Melting temperature 850-1000 °C

Statues, coins, bearings

A

Bronze

261
Q

Carbon fiber reinforced plastic (CFRP) composite and properties and uses

A

Carbon fibres mixed with polyester 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, helmet, prosthetics

262
Q

What is work hardening- metal enhancement

A

Work hardening is when the metal is ‘cold worked’ such as by bending,
rolling or hammering.
* the crystals within the metal are distorted and changed, leading to improved tensile strength and hardness in the worked area
*When the metal crystals are distorted, they cannot move freely within the metal structure, which can result in less ductility, cracking or damage in the worked area
* The effects of work hardening can be removed by annealing the metal.

263
Q

Low temperature pewter
casting

A

Redistribution

Molten metal from a billet

Jewellery, key fobs and
decorative components

  • Used for school or college projects.
  • Can be used with simple MDF moulds.
  • Suitable for one- off production or small batch
    (with aluminium moulds).
264
Q

should you you draw the mould in the shape of the product?

A

Add this:a polymer manufacturing process for a TV remote
control’ - make sure that, in the diagram, you draw the
mould in the shape of the product.

265
Q

What is an electrical insulator

A

A material that does not allow the flow of electricity

266
Q

All non ferrous-metals

A

Aluminiu, copper, zinc, silver, gold, titanium, tin

267
Q

Bending- Paper and board forming
processes

A
  • The stamped-out net is placed on to a folding table.
  • Some die cutters may include moving parts that help to bend or fold parts of a net automatically. For example, when making boxes, the die
    cut net is held firmly while the sides are bent up along the crease lines.
268
Q

Thin layers of wood are placed and glued at 90 degrees to one another and compressed to form the board. Good strength in all directions, no grain weakness, always has an odd number of layers.

Structural work, desktops, indoor furniture, floorboards

A

plywood

269
Q

What is hardness

A

The ability to resist abrasive wear such as scratching and surface indentation

270
Q

What are the industrial tests for malleability and ductility

A

A bend test is used to determine how well a material can withstand cracking during one continuous bend. A test piece is placed in a bending machine and held; supported at the ends. A plunger loads the test piece at the centre and bends to a predetermined angle. The material is then inspected for cracks and defects.
Cracks on the outer bend indicate the level of ductility
Cracks on the inside of the bend indicate the level of malleability.

271
Q

Tough, hard, good chemical resistance, available in translucent. Safe working temperature 95 °C.

Car light casings, computer numerically controlled (CNC) laser- cut items, lighting units, lighting covers,bath

A

Polymethylmethacrylate (PMMA)

272
Q

What is a smart material

A

When a material’s physical property changes in response to an input or change in the environment like light temp or electricity

273
Q

Milling

A

The work to be machined is clamped on to the table of the machine.
The table can run in the x direction (left and right horizontally), y
direction (forwards and backwards horizontally) and z direction (up and
down vertically) to cut slots, shape edges or thread holes.

274
Q

Chemically treated to brighten the surface to make it
suitable for high-quality printing.

Greeting cards, high-quality
packaging

A

Bleached card

275
Q

Tough, excellent wear resistance against friction, good thermal resistance against friction, electrical insulator

Vehicle tyres, shoe soles, toys, conveyor belts, water and pneumatic hoses

A

Butadiene rubber (BR)

276
Q

How long till bio-polymers degrade

A

can be designed to degrade in as litle time as a few months to a couple years

277
Q

What is the industrial test for tensile strength

A

A standard test piece of material is placed into a Tensometer machine and held in clamps at each end. One of these moves on a worm drive gear putting the piece under constant tension. The ostretch is measured before the piece ‘necks’ and reaches final breaking point.

278
Q

Translucent paper, slightly thicker than layout paper.

Copying images when sketching

A

Tracing paper

279
Q

High-density
polyethylene (HDPE) properties/ performance characteristics and uses

A

Available in translucent form, weather proof, tough, good chemical resistance. Safe working temperature 65 °C.

280
Q

Transparent, tough, naturally biodegrades.

Packaging film, membranes, photographic films

A

Celulose acetate

281
Q

What are manufactured boards

A

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

282
Q

What are metal processes grouped into and what are they

A

forming - processes in which no material is removed, but materials are deformed to produce required shapes

redistribution - processes where the material is changed from one form
to another without loss of material e.g. liquid metal poured into a mould
to take a solid shape

wastage - processes that cut away material to leave the desired shape.

283
Q

All composite materials

A

Carbon fibre reinforced plastic (CFRP), glass fibre
reinforced plastic (GRP), tungsten carbide, aluminium
composite board, concrete, fibre cement, engineered
wood, e.g. glulam

284
Q

All thermoplastics

A

Low density polyethylene (LDPE), high density polyethylene (HDPE), polypropylene (PP), high
impact polystyrene (HIPS), acrylonitrile butadiene
styrene (ABS), polymethyl methacrylate (PMMA),
polyethylene terephthalate (PEl), nylon, rigid and flexible polyvinyl chloride (PVC)

285
Q

MDF properties/ performance characteristics and uses

A

MDF is compressed wood fibres, 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 or mould making, furniture items such as bookcases, cabinets and desks

286
Q

What are the wood-forming processes

A

Lamination, steam bending, turning-milling and routering

287
Q

Two outer layers of card with a foam middle core

Mood board backing, presentation boards, modelling

A

Foam board

288
Q

What are all ferrous metals

A

low carbon steel, medium carbon steel, cast iron

289
Q

Kiln seasoning

A

is expensive, using controlled temperature and humidity levels.
* The wood is stacked on trolleys.
* It is initially steamy in the kiln then becomes hotter and drier.
* It is a quick process, taking up to a few weeks.
* The wood is used for indoor products.

290
Q

Hard tough

Blanking punches and dies,
extruder dies, fine press tools

A

Die steel

291
Q

turning

A

This is carried out on a centre lathe.
* Work such as a bar can be held in a rotating chuck and machined to reduce the diameter, and to square or ‘face off’ the end, thread and drill.
* Turning can be done manually or using computer numerically controlled (CNC) lathes.
* The material is machined by cutting tools held in a tool post, which can be moved in and out, and along the bar.

292
Q

Ductile, malleable, tough, corrosion resistant, good electrical and thermal conductor, can be soldered
and brazed. Melting temperature 1083 °C.

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

A

Copper

293
Q

An odd number of layers glued together with the two outer layers made from open-grained timber, which allows the sheet to flex. Bent and glued around a former to achieve a solid shape.

Laminated furniture, curved panels

A

Flexible plywood

294
Q

Glycolide (Lactel and Ecofilm) type and source and uses

A

Bio-polymer (synthetic). Fully compostable. PLA and cellulose based.

Food film, bags, packaging wrap, bin bags, agricultural ground sheet, flower wrap

295
Q

tough attractive open grain pattern which makes it more flexible

tool handles ladder sports goods laminating

A

Ash

296
Q

Gravity die casting process type, process diagram, stock form, products, key features

A

uses gravity to force the molten material into the mould.

Redistribution

Molten metal from a billet

Alloy wheels, engine components, door knobs and handles

  • Lower melt point metals such as aluminium, aluminium alloys and zinc-based alloys
  • Relies on gravity to help the metal
    flow into the mould.
  • Used for thicker mould sections.
  • Used for very large-batch and mass production.
297
Q

transparent tough naturally biodegradable

Biodegradable packaging film

A

Polylactide

298
Q

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

Fire exit signs, ‘glow in the dark’ products such as adhesive stars, masks, night lights, watch hands

A

prosphorescent pigment

299
Q

Butadiene rubber (BR) properties/ performance characteristics and uses

A

Tough, excellent wear resistance against friction, good thermal resistance against friction, electrical insulator

Vehicle tyres, shoe soles, toys, conveyor belts, water and pneumatic hoses

300
Q

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

A

Duplex card

301
Q

Flexible plywood properties/ performance characteristics and uses

A

An odd number of layers glued together with the two outer layers made from open-grained timber, which allows the sheet to flex. Bent and glued around a former to achieve a solid shape.

Laminated furniture, curved panels

302
Q

Resin uses wood

A

Used in engineered wood (e.g. manufactured boards) to enhance theproperties of the useable parts of trees such as sawdust, wood chips and fibres.Chipboard is made from compressing wood chips with a resin

303
Q

Extrusion diagram, Polymer stock form, Products, Key features

A

similar to Injection Moulding but without the use of a hydraulic ram as the polymer is continually pushed through the die due to the archimedean screw

Thermoplastic granules

Solid rods, tubing, angle sections, curtain track

  • Like injection moulding except polymer is forced through a die.
  • Industrial production method.
  • Continuous production.
304
Q

Fillers reason to add it

A

Sawdust and wood flour provide bulk to the product, meaning that less polymer is required. Mineral fillers such as chalk, clay and calcium carbonate help increase the thermal conductivity of the polymer, meaning it will heat up and cool down more quickly, which gives shorter mould cycle times.

305
Q

Calendering diagram, Polymer stock form, Products, Key features

A

Thermoplastic pallets

thin polymer sheet and films

  • Heated rollers squash and stretch the polymer to make it thinner.
  • Industrial production method, carried out by specialist manufacturers.
  • Used for continuous production.
306
Q

Lubricant reason to add it

A

Adding wax or calcium stearate reduces the density of the molten polymer, making it less ‘sticky’ and allowing more complex shapes to be formed. Lubricants also allow the moulding temperature to be lowered, saving energy.

307
Q

Hard, tough, straight grain, natural oils resist moisture, acids and alkalis.

Outdoor furniture laboratoy benches traditional boat decks

A

Teak

308
Q

What are the types of woods

A

Hardwoods, Softwoods and manufactured boards

309
Q

Tungsten carbide composite and properties and uses

A

A cermet (mixture of ceramic and metal particles) Ceramic tungsten and cobalt metal

Hard, tough, resistant to high temperatures, corrosion resistant

Cutting tools such as drill bits router bits kitchen knifes

310
Q

Tough polymer sheet. Can be folded millions of times. Virtually impossible to tear, water resistant.

Packaging products, folders, boxes

A

Translucent PP sheet

311
Q

What is lamination as a wood process

A

This bonds materials together.
* It uses wood veneers or thin manufactured boards such as 3 mm plywood, which can be glued together and bent over a former
so that, when dry, they form a thicker board
in the shape of the former.
* Held while drying by clamps or a vacuum bag.

312
Q

Reinforced concrete composite and properties and uses

A

Cement powder, sand, aggregate particles and low carbon steel rods (rebar) mixed with water

High compression and tensile strength, consistency across the structure, few surface defects, fire resistant

Buildings, bridge piles and bridge spans, retaining walls, grid floors

313
Q

Malleable, low melting point
170-230°C, casts well.
85-99% tin, with the remainder
consisting of copper and antimony.
Melting temperature 170-230 °C.

Tankards, flasks, goblets,
photo frames, decorative items,
candlesticks, sports trophies

A

Pewter properties/ performance characteristics and uses

314
Q

Injection moulding diagram, Polymer stock form, Products, Key features

A

Materials is put in a hopper, mixed heated up whilst being moved by a archimedium screw then forced into a mould due to a hydraulic ram. It cools and hardens in the mould.

Thermoplastic granules

Electrical product casings (computers, TVs, vacuum cleaners, calculators)

  • Complex 3D shapes can easily be made.
  • Fast industrial production method
  • High initial tooling cost.
  • Used for large-scale mass or continuous production.
315
Q

Tin properties/ performance characteristics and uses

A

corrision resistent, low meting point, Melting temperature 232 °C.

soft solder, coatings for food cans, rarly used in pure from

316
Q

What types of questions can be answered using mechanical and physical properties?

A

Materials properties of products and say why the property is needed

317
Q

Lamination (lay up) diagram, Polymer stock form, Products, Key features

A

Fibre-based composite sheets (GRP, CFRP)

Boat hulls, kayaks, train carriages, theatre and film props, theme park rides

  • Requires a former to mould around.
  • Polyester resin used as the polymer.
  • A top gelcoat is applied which may contain pigment.
  • CFRP requires an autoclave for the product to ‘cure.
318
Q

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

A

Engineered wood

319
Q

Pressure die casting
(cold chamber) process type, process diagram, stock form, products, key features

A

Die casting is a process where molten metal is forced into a mould under high pressure. The mould is made from two strong steel dies that fit together to form the shape.

Similar to hot chamber in the process except the molten metal is stored elsewhere and ladled into the machine for each SHOT. Mainly for Aluminium because it can pick up particles of steel from the chamber in the hot process

Cold-chamber machines: For metals like Aluminium.

Redistribution

Molten metal from a billet

Toy cars, collectible figures, decorative door knobs and handles

  • Lower melt point metals such
    as aluminium, aluminium alloys and zinc-based alloys.
  • Molten metal ladled into the shot chamber and hydraulically pushed into the chamber.
  • Used for very large-batch and mass production.
320
Q

Beech properties/ performance characteristics and uses

A

Tough, close grained, hard, available in steamed (white colour) and un-steamed (pink tinge).

Chairs, chopping boards, tools (mallet), steam bent laminated furniture, turned bowls

321
Q

Dense, closed-cell foam. Can be cut, shaped and sanded with standard workshop tools.

Product modelling, formers for moulding and laminating

A

Styrofoam

322
Q

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 takeaway boxes

A

Corrugated card

323
Q

Thermal antioxidants reason to add it

A

Prevent the polymer oxidising or discolouring due to excessive heat during processing.

324
Q

What is a composite material

A

A material made of two or more different materials enhancing the material properties

325
Q

Translucent PP sheet properties/ performance haracteristics and uses

A

Tough polymer sheet. Can be folded millions of times. Virtually impossible to tear, water resistant.

Packaging products, folders, boxes

326
Q

What is torsional strength

A

The ability to withstand twisting forces from twisting/torsion

327
Q

Plywood made from 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

A

Aeroply

328
Q

Straight grain, can corrode ferrous metals due to acidic nature, low density, good sound damping rot and insect resistant

Exterior cladding, sheds, greenhouses, beehives, interior panelling

A

Cedar

329
Q

Very tough, good chemical resistance,
weather proof, available in translucent, low level of rigidity. Safe working temperature 65 °C.

Squeezy detergent bottles, toys,
carrier bags, bin liners, general
packaging, food wrap film, food
trays

A

Low-density
polyethylene (LDPE)

330
Q

Birch properties/ performance characteristics and uses

A

Hard, straight close grained, resists warping

Furniture indoor panelling veneers used for birch faced plywood constructions

331
Q

Aluminium composite board composite and properties and uses

A

Aluminium sheets with a polyethylene core

Lightweight, rigid, tough, malleable, good thermal and sound insulation, good vibration damping.

Soundproofing panels in cars, buildings and boats

332
Q

Electroluminescent
wire how does it work and uses

A

Thin copper wire coated in a phosphorescent material that glows
in response to an alternating current

Glow bracelets, interweaving for clothing, home decoration, outdoor decorative lighting

333
Q

What resin is used for indoor flouring and how

A

Resin is impregnated with fire-retardant cladding

334
Q

Flexible polyvinyl chloride (PVC) properties/ performance characteristics and uses

A

Available in translucent, tough, flexible,good weathering resistance, goodchemical resistance. Safe working temperature 95 °C.

Hose pipes, cable insulation, medical grade tubing, inflatable products, imitation leather, seat coverings

335
Q

Mouldings wood stock form

A

Pre-made mouldings such as skirting boards or wooden trims are readily available in standard lengths up to approximately 4 metres.

336
Q

What is compressive strength

A

The ability to withstand being crushed by pushing forces

337
Q

Workshop test malleability and ductility

A

A test piece is secured in a vice and then it is attempted to bend to 90 degrees using a hammer or mallet.
Cracks or surface damage on the outside of the bend indicate a lack of ductility. Cracks on the inside indicate a lack of malleability.

338
Q

Turning purpose and methods

A

This process machines wood on a lathe. There are three turning methods:
1 turning between centres, used to machine a spindle such as chair legs and table legs
2 turning on a faceplate, used to machine items such as domes or bowls
3 turning in a chuck, used to grip the item while it is machined, such as drilling the end of a spindle or holding the base of a small bowl to allow access to the inside
surface.

339
Q

Plasticisers reason to add it

A

Allow plastics to become less hard and brittle at normal temperature use,e.g. added to LDPE food wrap, allowing the wrap to be stretched over the food product

plasticisers also help in processing because they allow polymers to be easily formed at higher temperatures

340
Q

Tough, hard, corrosion resistant.
18% chrome, 8% nickel.
Melting temperature 1510 °C.

Sinks, kitchenware, cutlery

A

stainless steel

341
Q

Thermochromic pigment how does it work and uses

A

changes colour in response to temperature change

Room thermometers, medical thermometers for children, bath water thermometers, colour change mugs and kettles, food packaging to indicate food is hot to eat or cool for drinks, baby feeding spoons, battery charge indicator strips

342
Q

Styrofoam properties/ performance haracteristics and uses

A

Dense, closed-cell foam. Can be cut, shaped and sanded with standard workshop tools.

Product modelling, formers for moulding and laminating

343
Q

Thermoforming diagram, Polymer stock form, Products, Key features

A

Thermoplastic sheet approx 6 mm

Bath, food packaging, box, sandwich packaging

Like vacuum forming, except
for an additional. mould is pressed
onto the surface of the polymer sheet at the same time as
the vacuum is applied.

  • Good for fine detail such as
    moulding in logos.
  • Slow process, used in industrial production
344
Q

Tough, available in thin sheet
form. transparent good chemical resistance flexible

Food wrapping, air pillow packaging,
bubble wrap, carrier bags

A

Low-density polyethylene (LDPE) sheet

345
Q

What is a biopolymer and groups

A

Polymer derived from renewable biological sources, such as plants or microorganisms, as opposed to fossil fuels. Cannot be recycled and may contribute to a throwaway culture. can be classified into two groups:

Natural bio-polymers are made from natural materials such as cellulose, starch and polysaccharides.

Synthetic bio-polymers are made from renewable resources but chemically engineered (synthesised) to break down more quickly.

346
Q

characteristics of metals

A

Metal is a naturally occurring material and is mined from the ground in the
form of ore.

they are grouped as ferrous, non ferrous and alloys

  • Approximately 25 per cent of the Earth’s crust is made up of metal ores.
  • Bauxite, which aluminium is made from, is the most common ore.
  • The raw metal is extracted from the ore through a combination of
    crushing, smelting or heating, with the addition of chemicals and huge
    amounts of electrical energy.
  • Metals can easily be recycled (due to their low melt point)
347
Q

Stock forms of polymers

A

Granules: a smal particle of plastic.
* Sheet: large flat sections of polymer in varying thicknesses.
* Film: very thin sheet polymer.
* Rods and other extruded forms, tubes, bars: rods and extruded
forms can be a specific designed shape
* Foam: solid form made by including air or other gases, such as
styrofoam from expanded polystyrene.
* Powder: very fine granule of polymer.

348
Q

Examples of hardwoods

A

Oak, ash, mahogany, teak, birch and beech

349
Q

Duralumin properties/ performance characteristics and uses

A

Equivalent strength properties to
mild steel but more light weight,
ductile, becomes harder as it is
worked. Aluminium with 4% copper, 1%
magnesium and manganese.

Aircraft parts, vehicle parts

350
Q

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

veneers, plywood construction, joinery and construction work

A

Douglas fir

351
Q

Uses of cutters

A

Cutters are used to cut out ‘nets’ or ‘developments’ that, when folded and assembled, will form a 3D shape such as a box.

352
Q

Steel cutting dies uses

A

Steel cutting dies (to cut the paper or board) and creasing rules (to crease areas for folds) are used to cut out the net shape from the sheet of paper or board, ready for assembly.

(in industry some machines will cut, crease and fold the edges to create
the 3D shape in one process.)

353
Q

Melamine formaldehyde (MF) properties/ performance characteristics and uses

A

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

Decorative laminates, picnic ware, buttons

354
Q

Stainless steel properties/ performance characteristics and uses

A

Tough, hard, corrosion resistant.
18% chrome, 8% nickel.
Melting temperature 1510 °C.

Sinks, kitchenware, cutlery

355
Q

Structural composite
lumber (SCL) and
laminated veneer
lumber (LVL) uses wood enhancement

A

Made by layering strands (SCL) or veneers (LVL] of wood with resins such asurea formaldehyde, pressing and heat curing them to produce a stable wood billet. SCL and LVL are less prone to defects such as warping, splitting or shrinking. and have greater load bearing properties

356
Q

Workshop electrical conductivity test

A

multimeter with the probes attached at a set distance between them. The higher the resistance, the lower the conductivity.

357
Q

Investment casting process type, process diagram, stock form, products, key features

A

Make the Wax Pattern: Create a wax model of the product.
Assemble the Tree: Attach wax patterns to a central sprue.
Dip in Ceramic Slurry: Invest the tree in liquid ceramic. Stuccoing sand after for strength.
Dry the Shell: Let the ceramic shell harden.
Melt the Wax: Heat the shell to remove the wax.
Preheat the Mould: Heat the shell to prevent cracking.
Pour Molten Metal: Fill the hollow mould with metal.
Cool the Casting: Let the metal solidify inside.
Knockout: break the ceramic mould revealing the cast tree
Finishing: Remove the parts from the tree and finish the edges.

redistribution

molten metal from a billet

Cast jewlerry or collectable figures, hip replacement joints

Used for intricate or awkward shapes that would be difficult or impossible to mould using any other casting process.
* High quality, excellent finish.
* Wax patterns are cast from a master mould, a repeatable quality process

358
Q

types of seasoning for woods

A

Air and kiln

359
Q

Silver

A

Malleable, ductile, corrosion resistant, can be soldered. Melting temperature 962 °C.

Jewellery, cutlery, used for plating other materials

360
Q

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

Furniture, flooring, boat building, lading, interior and exterior joinery

A

Oak

361
Q

Hard, tough, attractive grain pattern, fades to silver upon exposure outside

Garden furniture, cladding, decking and fencing

A

Larch

362
Q

Douglas fir properties/ performance characteristics and uses

A

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

veneers, plywood construction, joinery and construction work

363
Q

Neoprene (polychloroprene rubber) properties/ performance characteristics and uses

A

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

Wetsuits, laptop cases, industrial wire insulation, automotive applications such as shock absorber seals, hose covers, transmission belts, gaskets and door seals

364
Q

metal enhancement- Annealing

A

Annealing is used to make the work-hardened metal easier to work by
making it less brittle and more ductile.
* The metal is heated and then cooled very slowly, allowing the metal
crystals to grow and slowly move into place.

365
Q

Rolling -process type, process diagram, stock form, products, key features

A

where metal is passed through rollers to reduce its thickness and shape it. This can be done using hot rolling or cold rolling, depending on the temperature and the desired properties of the final product.

Forming

billet

Hot rolling: 1 beams, angle,
bar, plate and channel, railway tracks

Cold rolling: filing cabinets, chairs, steel drums, containers

  • Hot rolling metal results in uniform mechanical properties, np deformation stresses.
  • surface is usually coated with carbon deposits, which must be removed using acid pickling.
  • Cold rolling results in a material that has a tighter tolerance and better surface finish.
366
Q

Bio-polymer (synthetic). Fully compostable, water soluble. PLA and cellulose based.

Biomedical applications, slow- release medication, bone repair fixings, detergent washing sachets

A

Lactide

367
Q

Characteristics and explanation of wood

A

Wood is a natural material, which wil naturaly biodegrade if left in landfill.
Wood fibres grow along the length of the tree or branch (grain) and these fibres consist of hollow cells (tracheids) supported by lignin resin.
2 types hardwood and softwood

Wood
expands and shrinks with changes in humidity.
Wood is:
* strong in the direction of the grain (along the grain) and weaker across
the grain
* converted (from the tree it is sawn into useable pieces) and then seasoned (air or kiln) to remove the excess moisture, 80-90 per cent, before use
* seasoned to help prevent defects such as twisting, warping, cracks, cupping or bowing; to reduce the time taken t o season wood, trees should be felled in the winter when they grow less, have less sap and
therefore contain the least moisture.

368
Q

Hard, rigid, available in translucent, tough. Safe working temperature 70 °C.

Yoghurt pots, refrigerator linings, single-use drink cups, toilet seats, instrument control knobs

A

High-impact polystyrene
(HIPS)

369
Q

Duplex card Properties/performance characteristics

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

370
Q

What is Non-destructive testing (NDT) and methods

A

is usually carried out on products such as large castings where there is a likelihood of internal defects or imperfections which might not be detected by other methods. There are two standard NDT methods:

Ultrasonic testing: a transducer generates sound waves which are pulsed into the material. The intensity of the reflected waves is recorded on a display unit. They can show internal cracks or other defects and can be used on all types of materials.

X-ray testing: an x-ray beam passes through the material and an image is projected onto a display screen. X-ray testing can be used to inspect integrated circuits (IC’s) and printed circuit boards (PCB’s) and to check for micro-voids in composite materials in products such as Formula One cars. It can also be used to detect faults in turbine blades or aeroplane engine blocks.

371
Q

What is a thermal conductor

A

A material that allows the transfer of heat energy (high conductivity = quick transfer of heat)

372
Q

Bleached card Properties/performance characteristics and uses

A

Chemically treated to brighten the surface to make it
suitable for high-quality printing.

Greeting cards, high-quality
packaging

373
Q

Ash properties/ performance characteristics and uses

A

tough attractive open-grain pattern which makes it more flexible

tool handles, ladder, sports goods, laminating

374
Q

What is thermal expansion

A

the increase in material volume in response to heat increase

375
Q

Changes shape in response to a change in temperature or electrical input, e.g. nitinol wire in dental braces can change at body temperature when placed in the mouth to mantain constant tension

Dental braces, self-closing windows, aeroplane wing flaps, bioengineering such as stents, bone plates and screws

A

SMAs, e.g. nitinol

376
Q

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

A

Nylon

377
Q

Resins with fire retardants uses

A

Resin is impregnated with fire-retardant cladding (e.g. for indoor flooring). which slow down the spread of fire.

378
Q

Antioxidants reason to add it

A

Help reduce the environmental damage of the polymer from exposure to oxygen in the air.
Also help prevent increased brittleness, surface cracks and pigment discolouration. Often used in polymer garden furniture.

379
Q

Potatopak type, source and uses

A

Bio-polymer (natural). Made from potato starch.

Single-use food items such as bowls, cutlery, food trays, serviettes, packaging beads or peanuts, bin bags

380
Q

What are all the metal enhancement

A

Work hardening, annealing, case hardening, hardening, tempering

381
Q
A

Product design (2 decks)

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