1. Engineering Materials Resource 4 Manufacturing Techniques

2. Edexcel Principles of Learning in Engineering Resource 4 Aims & Objectives Identify engineering materials & uses Differentiate metallic & non-metallic materials Understand the hardening & tempering processes

3. Edexcel Principles of Learning in Engineering Resource 4 Select appropriate materials for manufacturing activities Identify materials properties & uses Manufacturing processes for a range of materials Harden & temper materials Aims & Objectives

4. Edexcel Principles of Learning in Engineering Resource 4 Materials

5. Edexcel Principles of Learning in Engineering Resource 4 Ferrous Metals Mild steel Cast iron Wrought iron High carbon steel Stainless steel

6. Edexcel Principles of Learning in Engineering Resource 4 Uses Mild steel – Structures, Bridges, Steel products, Nuts & bolts Cast Iron – Castings, Engines, Machine vices Wrought Iron – Gates, railings High Carbon Steel – Tools, drills, centre punch, chisels, files Stainless Steel – Cutlery, Kitchen & bathroom appliances, medical instruments

7. Edexcel Principles of Learning in Engineering Resource 4 Non Ferrous Metals Copper Brass Lead Aluminium Silver Gold Zinc

8. Edexcel Principles of Learning in Engineering Resource 4 Uses Copper – Pipes, electrical wiring, kitchen ware Brass – musical instruments, tableware, ornaments Lead – Batteries, soldering, roofing & cladding Aluminium – Aircraft, Window frames, Kitchen ware, cans Silver – Jewellery, coins, cutlery Gold – Jewellery, coins, cutlery, dentistry Zinc – Galvanising steel products

9. Edexcel Principles of Learning in Engineering Resource 4 Alloys Some metals can be used in their pure form or combined with other metals to produce an Alloy metal. An alloy is a combination of two or more metals to improve the mechanical properties of the materials. A few materials are listed below: - Brass Bronze Stainless steel High carbon steel

10. Edexcel Principles of Learning in Engineering Resource 4 msc-ks4technology.wikispaces.com Forms of supply Materials can be cut in various shapes & sizes. Round Flat Square Hexagonal Octagonal Sheet Channel Angle Square Tube Round Tube

11. Edexcel Principles of Learning in Engineering Resource 4 Grain Structures users.aber.ac.uk Crystalline & Amorphous

12. Edexcel Principles of Learning in Engineering Resource 4 Crystalline During the solidification process, crystals begin to form, multiply and grow until the material is completely solidified. These crystal contain atoms that are packed tightly together forming patterns.

13. Edexcel Principles of Learning in Engineering Resource 4 Amorphous Rapidly increasing the cooling rate during the solidification process can produce minuscule micro crystals or in some cases amorphous that is, non-crystalline solid liquid metals. The non-crystalline liquid structure is retained since the opportunity for crystallisation is avoided due to the extreme temperature change.

14. Edexcel Principles of Learning in Engineering Resource 4 Heat treatment processes Hardening Hardening is accomplished by heating the material (metal) to a required temperature between 800°C & 1500°C (depending on the properties required) then quenching in either oil or water. Tempering Tempering consists of re-heating the material between 200°C & 600°C (depending on the properties required) then quenching in either oil or water.

15. Edexcel Principles of Learning in Engineering Resource 4 Case Hardening Case hardening produces a hard, wear resistant surface on low carbon steels. The process is accomplished by heating the material between 800°C & 1500°C and infusing carbon elements onto the materials surface. Re-heat material between 800°C & 1500°C (depending on the properties required) then quenching in either oil or water.