Year 12 content Flashcards

Question

Polymer stock forms...

Answer 1

- Granules - Sheet - Powder - Film - Rods - Foam

Answer 2

Layout paper: - Thin + transluscent with a smootgh surface - Uses involve sketching, drawing and tracing. Treated paper: - Plain paper with a clear binder or dye layer to help hold image in paper surface. - Uses involve photographic painting.

Answer 3

Moulded paper pulp: - Recycled + smooth inside with rough outside - Uses include fruit packaging and egg boxes, making it foodsafe. Duplex card: - Coated water-resistant exterior, good aesthetics and waxy feel. - Uses include food packaging, making it food safe. Corrugated card: - Outer carton board layer + corrugated middle layer and is impact resistance + food safe - Uses involve food packaging, model making + prototypes | (All are foodsafe, with corrugated card being impact resistant).

Answer 4

Fluted PP: - Lightweight with flutes. - Uses involve road signage, small models etc. LDPE: - Tough and flexible + chemical resisitance with thin sheet available. - Uses involve food wrapping, carrier bags, bubble wrap etc... Polylactide: - Tough + transparent and naturally biodegrades. - Uses involve biodegradable packaging film/ | (Polymer sheet available 3mm,5mm,10mm and 20mm).

Answer 5

Rough sawn - Directly from seasoning with rough surfaces PSE - Wood has just one planed edge, (taking 3mm off). PAR - All sides and edges are planed, (board perhaps 3mm smaller than rough sawn). Manufactured board - Size is 1220mm x 2440mm + Wide surfaces can be produced without need for joining processes. Mouldings - e.g. skirting boards or wooden trims are readily available. | (Wood is strong along the grain and weak across, can be seasoned) ## Footnote Moisture can be removed

Answer 6

Air seasoning: - Wood stacked outdie, with air circulating to remove excess moisture. - Used for outdoor products. Kiln seasoning: - Wood stacked in a kiln, and removes excess moisture quckly. - Used for indoor products. | (80%-90% moisture removed)

Answer 7

- Thermoplastic - Thermoset - Elastomer (a material than can be deformed under pressure at room temperature)

Answer 8

LDPE: - Tough, chemical + weather resistant, HOWEVER, low rigidity - Uses involve detergent bottles, food wrapping + carrier bags (HDPE same but more robust + uses involve buckets, jerry cans, bowls) HIPS: - Rigid, hard + tough with low melting Uses involve point - Uses involve yoghurt pots, drink cups, control knobs etc. ABS: - Tough + hard, chemical resistant - Uses involve calculators, domestic appliances, phone handsets etc. PVC: - Tough + flexible, chemical + weather resistant - Uses involve hose pipes, cable insulation, seat coverings etc...

Answer 9

UF: - Hard, heat resistant + good electrical conductivity HOWEVER, brittle - Uses involve electrical fittings + adhesives MF: - Hard + tough, chemical + heat resistant and is foodsafe - Uses involve kitchen worktops, buttons etc PR: - Rigid, chemical + heat resistant HOWEVER, brittle - Uses involve lay-up lamination, car parts + boat hulls ER: - Hard + tough, chemical resistant and rigid - Uses entail adhesives, aerospace applications and surface coatings

Answer 10

Natural rubber: - Tensile strength + electrical insulator and tough + hard and cold resistant. - Car tyres, footwear, toys and other autmotive uses. BR: - Tough + electrical insulator and thermal resistant + good friction resistance - Uses involve car tyres, toys, conveyor belts + pneumatic hoses Neoprene: - Tough + electrical insulator and thermal + chemical + oil resistant - Uses involve wetsuits, laptop cases and automotive applications e.g. car tyres.

Answer 11

- Natural bio-polymers are from natural materials e.g. cellulose. - Synthetic bio-polymers are from renewable sources that are chemically engineered to break down fast. ## Footnote (Biodegradable polymers are from finite resources e.g. crude oil which degrade faster than traditional polymers)

Answer 12

- May leave behind toxic chemicals once decomposed, from high temperatures - Cannot be recycled - Can be processed in the same way as thermoplastics e.g. injection moulding, vacuum forming etc +++ - | +++ = pros

Answer 13

Potatopak: - Made from potato starch. - Uses involve single-use food items e,g, cutlery, serviettes etc PLA: - Made from corn kernels/sugar canes. - Uses involve 3D printing, packaging, bottles, carrier bags etc. Lactide: - Made from synthetic bio-polymer. - Uses involve detergent sachets, biomedical applications, bone repair fixings etc. | (Most have food uses)

Answer 14

Oxy-degradable - Polymer turns into powder with oxygen exposure Photodegradable - UV rays break down polymer Hydro-degradable - Polymer broken down with water exposure

Answer 15

Aluminium composite board: - Tough + lightweight and good thermal + sound insulation - Uses involve shop signage, soundproofing car panels and boats. Tungsten carbide: - Hard + tough, high temperature + corrosion resistant - Uses involve drill bits, kitchen knives etc

Answer 16

SMAs: - Changes shape in response to temp change or electrical input - Braces, screws, self-closing windows, plane wings etc. Photochromic pigment: - Changes colour with light intensity. - Uses involve security markers, welding goggles etc. Electroluminiscent wire: - Thin copper wire coated in a phosphorescent material, that glows in response to a change in currrent. - Uses involve glow bracelets, home decoration etc Piezoelectric material: - Releases a small electrical charge when deformed. - Uses entail airbags, pressure sensors, BBQ lighters etc.

Answer 17

Kevlar: - Aramid fibres that are cutproof and heat resistant. - Uses entail bulletproof vests, puncture-resistant tyres etc. PMC: - Fine material particles - Uses entail jewellery etc. Polymorph: - Granules that can be moulded and heated in water. - Uses involve modelling, prototype mechanical parts etc

Answer 18

Lubricants (reduces viscosity to allow formation of intricate shapes). Antistatic (reduce likelihood of static charge). Flame retardants (reduce combustion chances) Antioxidants Fillers (increases product bulk) Plasticisers (makes plastics less hard + brittle e.g. LDPE) - Perhaps acrylic spray paints and pigments for finishes

Answer 19

- Resins with fire retardants - Pigments for aesthetics. - SCL/LVL which prevents warping and boosts stability. - Laminations for protection - Preservatives to protect wood from fungal attack.

Answer 20

Work hardening - Boosts tensile strength + hardness via bending or rolling (crytal structure changed) Annealing - Boosts ductility + reduces brittleness (metal heated and cooled very slowly, allowing growth of crystals) Case hardening which hardens the outer layer of the metal -> Carburisng (low carbon steel) alters crystal structure with a heated steel box for industry -> Quenching sees the hot metal dipped in cold water and seal hard surface. Hardening (medium + high carbon steel) heated to alter crystal structure -> Quenching then takes places ---> This boosts hardness + brittleness Tempering - heat treatment removes excess hardness + brittleness of hardened metal -> boosts toughness + ductility -> metal then heated and slowly cooled, and tempering colour will indicate metal temperature | (In order)

Answer 21

- Vacuum forming (3D ligthweight products e.g food yoghurt pots) - Injection moulding (intricate casings e.g. TVs) - Thermoforming (used for other polymers or food packaging) - Calendaring (Thin polymer sheet and film) - Blow moulding (lightweight hollow products e.g. plastic bottles. - (lay-up) lamination (3D products from composites e.g. boats and yachts. - Line bending (used with acrylic e.g. phone stands). - Rotational moulding - Used for large wall thickness items e.g. traffic cones) - Extrusion - (used for 'I' or 'T' sections e.g. guttering) - Compression moulding (used for thermosets e.g. electrical plugs or picnic sets). | (Check google drive for more info)

Answer 22

- Cupping (e.g. fire extinguishers or drinks cans). - Drop forging (e.g. spanners and screwdrivers) - Wrought iron forging (e.g. decroative metalwoek e.g. gates of fencing) - Bending (e.g. product casings) | (Check google drive for more info)

Answer 23

- Hot chamber, cold chamber and gravity die casting (used with low-melting point metals e.g. zinc e.g. door handles, engine components and alloy wheels). - Sand casting is used for high melting points (e.g. park benches or post boxes). | (Check google drive for more info)

Answer 24

MIG welding: Used for thin metal sheets, usually tube or box section - aluminium or medium carbon steel -> e.g. bike frames, car exhausts etc. ---> a heated electric arc melts joint area -> gap is filled with wire electrode melting in the arc TIG welding: Used for non-ferrous metals, stainless steel and alloys. -> e.g stainless steel car exhausts or ladders. ---> similar to MIG welding however, filler rod is used rather than wire electrode melting in the arc. -> compared to MIG, better accuracy and quality cam be provided, meaning higher skill. Oxy-acetylene welding: Used when other welding forms are not available, however, useful for quick repair and no electricity is required. ---> Metal is prepared, an angle 'v' is grinded to ensure full welding coverage of metal thickness -> melt pool formed via heated joint area, and steel filler rod used simultaneously. -> melt pool forms bead on joint's length, allowing molten metal flow.

Answer 25

- Milling - Turning - Flame cutting (uses oxy-acetylene gas) - Plasma (electrically conductive) - Laser cutting - Punching/stamping (uses CNC to stamp out sections in sheet material)

Answer 26

Acrylic and cellulose paints: -> Applies a textured finish and a corrosion barrier. -> must be cleaned to allow the primer coat to grip the finish. -> can be used with a brush or spray. Electroplating: -> coats cheap base metal for enhanced protection and aesthetics. -> anode allows the cathode, (the object to be plated), to have the finish. -> e.g. metal teapots. Metal dip coating: -> metal is dipped into molten metal, and acts a corrosion barrier. -> e.g. car bodies. Powder coating: -> product to be coated is negatively statically charged, the positive thermoset PR is sprayed through an airgun. -> resulting in strong attraction between powder and product. -> product is baked in an oven -> coating provided with powder melted. e.g. bicycles Varnishing: -> protects the metal, and provides a clear finish, showing the colour. -> used on expensive metals, e.g. aluminium. -> surface grease should be removed with varnish applied either with a brush or spray. Sealants: -> protect polished surfaces from decay. -> normally applied with cloth or machine pad, which then allows the metal to cure, and is then buffed with a cloth to shine. -> automotive bodywork or polished exhaust pipes. Preservatives: -> often used on moulds or dies to prevent fingerprints showing up, and can be applied with a cloth or spray. Anodising: -> usually used for aluminium, boosting properties hardness and toughness, and can provide colour .-> current passes through sulphuric acid, to cathode -> aluminium oxide layer builds up on treated part as current travels from anode to cathode -> finish can then be varnished, e.g. for protection. -> e.g. motorcycle components. Cathodic protection: -> current flows between anode and cathode, between aluminium sheets. -> two types are impressed current and sacrificial anodes. -> sacrificial has another metal protecting metal + impressed current supplies current from negative electrode, to be protected. e.g. boats or ships

Answer 27

- PVA bonds wood/wood-based materials. - Contact adhesive can bond different materials together - Solvent cement bonds polymers together e.g. Tensol 12 - Epoxy resin bonds different materials and comes in resin or hardener

Answer 28

- Debossing produces an IMPRINTED depression - Embossing produced an outer decorative layer - UV varnishing + spot varnishing uses clear ink to enhance aesthetics - Foil blocking applies heat + pressure to foil to create texture for an aesthetic impact.

Answer 29

Pros: - High print speed - Low cost for equipment + consumables + low maintenance - Can print for long runs Cons: - Printing plates' costs high - Large amount of substrate may cause material wastage - Time consuming to alter print content | (CMYK and is the least costly printing process). ## Footnote Used in catalogues, labels, comics etc.

Answer 30

Pros: - Consistent high image quality - High volume print runs - Long life of printing plates Cons: - Expensive set-up + running costs. | (CMYK and metallic with ten-roller machine). ## Footnote Used in books, magazines etc.

Answer 31

- Water-based paints (provides protection and colour, outdoor + indoor usage) - Stains (adds colour) - Colour wash (enhances aesthetics) - Wax (good aesthetics and boosts hardness + toughness) - Danish oil (water-resistant) - Teak oil (good aesthetics and insect resistant) - Pressure treating (aids wood to be weather resistant + insect resistant for up to 50 years) and can be used for decking + bridges | (Polymers are self-finishing)

Answer 32

- Employs an efficient computerised overhead transporter system. - Improves quality and allows more labour efficiency.

Answer 33

- Reduces time taken to respond to orders

Answer 34

- A company owns its supply chain - Sub-assemblies set-up Pros: - Reduced rish of components' price rises - Brand protection and IPR and makes QA strategies easier. Cons: - Specialisation reduced - Rise in administration

Answer 35

- Manufacturing cells combine CNC machinery (e.g. lathes) to carry out a sequence of operations. - AGVs transport materials from different buffer zones.

Answer 36

- Manufacturing needed products - Via things like regular feedback meetings, waste reduction, better management etc.

Answer 37

- Sourced parts from external suppliers. - Reasons involve higher consistency, more sub-assemblies, components can be bought in bulk and more...

Answer 38

- Copyright legally protects work e.g. music, films etc - Patents gives legal rights for specific designs or systems - Registered designs JUST protect product apperance - Trademark gives legal protection for brand identity

Answer 39

production time / customer demand e.g. 1000 mins per day / 500 items per day = 2 mins | (Calculates working times etc)

Answer 40

- Uses small round pegs. - No specialist tools required. - Joining done via KDF fitting. - Dowel join via measuring holes, drilling and then applying glue. - Used in flat-pack furniture

Answer 41

- Similar to butt joints as it relies heavily on just gluing together. - Ends of material pieces to make 40 degree corner, and is then cut to 45 degrees. - Pieces are glued and clamped, and corners are straightened with a mitre jig. - Used in picture frames

Answer 42

- Used in box contruction

Answer 43

- Used to join timber pieces together (joints to be used are cut square) - Involves adhesive e.g PVA - Used for lightweight applications e.g. modelling

Answer 44

- Good directional strength - Used in drawers, as this gives good directional strength - Can be done by hand or can be machined by a router with a jig

Answer 45

- Used for heavy frame construction e.g. furniture - Involves a square or rectangular hole being made - Can be done with a chisel or via CNC - Uses PVA and a mortise to join pieces together

Answer 46

- Used in framework construction, cabinets and shelving. - Groove is cut on one piece and then other piece goes in it. - Joint is structurally strong and can be done by a chisel or a CNC router -

Answer 47

- Used to make simple frames or boxes. - Made by cutting a 'step' - These joints are easy to mark out and cut

Answer 48

- Used to make flat-pack furniture - Reduces cost for manufacturers and customers + This is transported and is not assembled. - Can be used on a wide range of products, as they are standardised and interchangable.

Answer 49

- Small, rigid polymer blocks - They take screws which are used to join block to panels - Typically used on used for cupboards and storage units. - Simple but not very strong and is unattractiuve + Becoming outdated in mainstream furniture manufacture.

Answer 50

- Cross-dowel used to fit into one of the pieces to be joined - Used in flat-pack furniture e.g. the frame of a bed or table.

Answer 51

- Turning - Routing timber - Milling timber

Answer 52

- Used in flat-pack furniture e.g. bookcases, where horizontal shleves are attached to the sides - Both pieces are held together tightly - Coach bolts have a thread that run about 2/3 of the way along the bolt. - Used for secure bolts or locks in wooden doors.

Answer 53

Lamination - Bonding materials together -> Former and veneers are placed under a polythene sheet Steam bending - Timber made pliable for former shape -> Combines heat and steam | (Check google drive)

Answer 54

- Engineered woods made by layering either veneers or strands of wood with resin e.g. UF -> Then pressing and heating used to produce a stable wood billet.