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Higher Product Design Materials© Learning and Teaching Scotland 2006
© Learning and Teaching Scotland 2006Staff guide Dear colleague, I produced this presentation to aid with the teaching of materials and their applications and hope that it will help you. Please feel free to edit it and change it to suit your own style and methods. The task slides are mostly designed to be copied onto note paper or into a jotter, with the exception of Task 10 which should be printed out and photocopied. If you have any comments on how this presentation could be improved or have any general feedback, please contact me at Please delete this slide before using the presentation with a class. © Learning and Teaching Scotland 2006
© Learning and Teaching Scotland 2006Materials Softwood Shape memory alloys Materials Wood Metal Plastic Composites Smart Ferrous metal Non-ferrous metal Thermoplastic Thermosetting plastic Hardwood Man-made board GRP CFRP Lenticular sheet Thermochromic film Polymorph Click on a material title © Learning and Teaching Scotland 2006
© Learning and Teaching Scotland 2006Wood Wood is an extremely useful natural material. It is hard and fibrous in nature and is made up of cells consisting of cellulose (natural resin) and lignin (the essential hard organic fibre). Wood is a natural polymer. There are three classifications of wood to be considered. These are: Hardwoods – slow-growing (100 years) Softwoods – quick-growing (30 years) Man-made boards – manufactured composites Click on appropriate star The terms hardwood and softwood refer to the rates at which the trees grow, rather than the type of timber produced from them. This is a botanical division and does not refer to the wood’s working properties. For example Balsa wood is a hardwood which is lightweight and very soft whereas Pitch pine is a softwood which is heavy and difficult to work. © Learning and Teaching Scotland 2006
© Learning and Teaching Scotland 2006Wood Hardwood Hardwoods are produced from deciduous (shed their leaves annually) and evergreen broad-leaved trees. These trees grow in regions with warm temperatures such as parts of Europe, New Zealand and Chile, and in tropical regions of central and South America, Africa and Asia. The growth of hardwood trees is generally slow, taking around 100 years. This makes hardwood expensive. Tropical hardwoods retain their leaves and therefore grow quicker and in much larger girth and height. There are ecological issues to be considered when using tropical timbers, and the destruction of the world’s rainforests has led to a shortage of tropical hardwoods. Hardwoods generally have more attractive grain structures, textures and colours, and greater durability than softwoods. Examples Beech Ash Walnut Elm Mahogany Ebony Oak Teak Meranti Oak bark © Learning and Teaching Scotland 2006
© Learning and Teaching Scotland 2006Task 1 Using research techniques find as many hardwoods as possible, and write their names down the left-hand column. In the middle column write down the working characteristic or properties of each hardwood and in the right-hand column find an application for each hardwood. Hardwood Working Characteristics Application © Learning and Teaching Scotland 2006
© Learning and Teaching Scotland 2006Wood Softwood Softwoods are mostly produced from evergreen conifers with thin needle-like leaves. These trees grow in regions of the Northern Hemisphere (such as Scandinavia, Canada and northern Europe) which have cold climates, and at high altitude elsewhere. The growth of softwood trees is much quicker than that of hardwoods and most become mature enough for felling in under 30 years. Softwoods are relatively cheap and are also easier to sustain by replanting. Softwoods can be easily identified by their open grain pattern and light colour. Straight grain gives a stronger timber which, being knot free, is easier to cut and shape. Examples Origin/colour Scots pine Northern Europe, Russia: Cream,pale brown Red cedar Canada, USA: Dark reddish brown Parana pine South America: Pale yellow with red/brown streaks Spruce (whitewood) Northern Europe, America: Creamy white © Learning and Teaching Scotland 2006
© Learning and Teaching Scotland 2006Task 2 Using research techniques find as many softwoods as possible, and write their names down the left-hand column. In the middle column write down the working characteristic or properties of each hardwood, and in the right-hand column find an application for each softwood. Softwood Working Characteristics Application © Learning and Teaching Scotland 2006
© Learning and Teaching Scotland 2006Wood Man-made boards are wood-based materials manufactured by bonding together wood strips, veneers (thin layers), pulp or particles. They represent a very important manufacturing material, particularly in the furniture industry. Manufactured boards have a number of advantages over wide wooden boards or planks: There is a limit to the number of wide boards that can be cut from a tree and this makes it expensive. Manufactured board is available in sizes up to 1525mm wide whereas hardwood is typically 300mm and softwood is 200mm maximum. Manufactured board is stable and of uniform thickness and consistent quality. © Learning and Teaching Scotland 2006
© Learning and Teaching Scotland 2006Wood MDF (or medium-density fibreboard) is made by compressing and gluing together tiny wood particles to form a dense board that is available in a wide range of shapes and cross-sections including mouldings and moulded panels. It is very stable and easily laminated with a thin plastic coating or hardwood veneer. MDF is used extensively for kitchen and workplace furniture. Plywood is formed in large presses from veneers (thin layers) of wood and bonded together with adhesive. This process is called laminating. The veneer is laid with the grain in alternate directions to achieve maximum strength. There is always an odd number of veneers (3, 5 or 7); this ensures flat faces and stability. Plywood is used for doors and applications where it is necessary to have thin sheet material, for example as drawer bottoms. © Learning and Teaching Scotland 2006
© Learning and Teaching Scotland 2006Wood Blockboard is made by gluing strips of softwood together, side by side, and then applying a thin veneer to the top and bottom surfaces. Blockboard is very strong and is used for furniture and heavy construction. Chipboard is made by compressing and gluing together tiny pieces of wood. It is not easy to work with and not very strong. It is, however, cheap and is usually used with a hardwood- or plastic-veneered face in cheap furniture. Hardboard is made by gluing and compressing pulped wood. Hardboard is thin and has one smooth surface and one textured. It is not very strong but provides a cheap substitute for plywood where strength is not of concern. © Learning and Teaching Scotland 2006
Task 3 Using research techniques, list eight man-made boards and a typical application for each. Man-made board Application 1. ………………………… ……………………………………………. 2. ………………………… ……………………………………………. 3. ………………………… ……………………………………………. 4. ………………………… ……………………………………………. 5. ………………………… ……………………………………………. 6. ………………………… ……………………………………………. 7. ………………………… ……………………………………………. 8. ………………………… ……………………………………………. © Learning and Teaching Scotland 2006
© Learning and Teaching Scotland 2006Metal Metals make up a major proportion of all the naturally occurring elements and form about a quarter of the earth’s crust. Gold is the only metal to be found in its pure state; all others are chemically combined with other elements in the form of oxides and sulphates. Metals are commonly available for manufacturing use in a wide range of forms and sizes. The range of sizes has to be vast because, unlike wood, metal cannot easily be converted from one size to another. © Learning and Teaching Scotland 2006
© Learning and Teaching Scotland 2006Metal There are two types of metal, ferrous metal and non-ferrous metal. Ferrous metal contains iron Non-ferrous metal does not contain iron A combination of two or more metals is called an alloy. An alloy is produced to have properties which could not be achieved with the individual substances. Click on appropriate star © Learning and Teaching Scotland 2006
© Learning and Teaching Scotland 2006Metal Ferrous metal Ferrous metals contain iron as the base metal. Historically they have played an important part in human development and remain vital to our everyday life. Almost all ferrous metals are magnetic. Steel is probably the most common ferrous metal; it contains carbon and its hardness depends on the amount of carbon it contains: e.g. mild steel is quite soft and contains 0.15 – 0.35% carbon, whereas high-carbon steel is very hard and contains 0.8 – 1.5% carbon. Examples of ferrous metal and alloy steels Cast iron Stainless steel Mild steel High-speed steel Medium-carbon steel High-tensile steel High-carbon steel Manganese steel © Learning and Teaching Scotland 2006
© Learning and Teaching Scotland 2006Task 4 Below is a list of examples of ferrous metals. Identify some of their properties, the carbon content and an application for them. Ferrous metal %Ca Application Pure iron Pig iron Wrought iron Low-carbon steel Medium-carbon steel Mild steel High-carbon steel High-speed steel Stainless steel Cast iron © Learning and Teaching Scotland 2006
© Learning and Teaching Scotland 2006Metal Non-ferrous metal Non-ferrous metals do not contain iron. Aluminium is the most plentiful metal in the earth’s crust and of all the non-ferrous metals it is the most used with regards to production output, due to its strength-to-weight ratio. Examples of non-ferrous metals and non-ferrous alloys: Aluminium Casting alloy Copper Duralumin Tin Brass Lead Bronze Zinc Tin plate © Learning and Teaching Scotland 2006
© Learning and Teaching Scotland 2006Task 5 List examples of non-ferrous metals. Identify some of their properties, the alloying element and an application for them. Non-ferrous metal Alloying element Application © Learning and Teaching Scotland 2006
© Learning and Teaching Scotland 2006Plastics This group of materials is not easy to define because it covers a wide range of diverse substances. A basic characteristic is that at some stage the material is putty-like (‘plastic’): it enters a state that is neither solid nor liquid, but somewhere in between. At this stage shaping and moulding by heat and pressure takes place before setting into the desired form. There are two groups of plastics: Thermoplastics Thermosetting plastics Forms of supply Click on appropriate star © Learning and Teaching Scotland 2006
Forms of plastic supplyPlastics can be supplied in various forms: Profiled sheets, rods, tubes and bars Moulded compounds Thin layers of film and sheets Foam Casting compounds such as ingots Paint, varnish and lacquer for finishing Filaments and fibres Composites which contain reinforcing material © Learning and Teaching Scotland 2006
© Learning and Teaching Scotland 2006Thermoplastics Thermoplastics (‘thermo’ – heat, ‘plastic’ – the condition between solid and liquid) are made up of long chain molecules that are entangled but not bonded together. This means that after its original shaping or forming a thermoplastic can be reheated or melted and return to a workable plastic state. This is called ‘plastic memory’ : because if you heat and bend a thermoplastic sheet, let it cool to solidify, and then reheat it, it will try to return to its original form. Here are some common thermoplastics: Polyethylene (HDPE/LDPE) Acrylic (Polymethyl methacrylate) Polypropylene (PP) Nylon (Polyamide) Polystyrene (PS) Cellulose acetate uPVC (Polyvinyl chloride) ABS (Acrylonitrile butadiene styrene) Plasticised PVC © Learning and Teaching Scotland 2006
© Learning and Teaching Scotland 2006Task 6 Below, list examples of thermoplastics, their properties and where they can be used: Thermoplastic Application © Learning and Teaching Scotland 2006
Thermosetting plasticsThermosetting plastics (thermosets) are also made from long-chain molecules like thermoplastics; but when the plastic is first formed the chains become chemically tied by covalent bonds (sharing of electrons) and are cross-linked. This causes the plastic to become rigid and non-flexible even at high temperatures. An egg yolk is a good analogy for this. When a yolk is raw it is in a soft liquid state, but if it is heated, it becomes hard and is no longer capable of becoming soft. Thermosetting plastics are often used when a product needs resistance to extremes in temperature, electrical current, chemicals and wear. Thermosets can resist impact when reinforced, an example being Glass Reinfored Plastic (GRP). Here are some common thermosetting plastics: Epoxy resin (ER) Urea formaldehyde (MF) Melamine formaldehyde (UF) Polyester resin (PR) © Learning and Teaching Scotland 2006
© Learning and Teaching Scotland 2006Task 7 Below, list examples of thermosetting plastics, their properties and where they can be used: Thermosetting plastic Application © Learning and Teaching Scotland 2006
© Learning and Teaching Scotland 2006Composite materials Nowadays products are increasingly being made from composite materials. A composite material has two or more substances which combine to produce properties (characteristics) that cannot be achieved by any of the individual substances. One of the substances forms the matrix (base material) and the other provides the reinforcement. The properties of the composite are controlled by the size and distribution of the reinforcing substance. Two examples of composite materials are: Glass fibre reinforced plastic (GRP) and Carbon fibre reinforced plastic (CFRP) Click on appropriate star © Learning and Teaching Scotland 2006
Glass-reinforced plasticThe mould is very important when forming GRP. The better the quality of the mould, the better the finish on the GRP. The moulds should be tapered to allow the product to be be removed easily. This is a forming process. Glass fibre is combined with polyester resin (thermosetting plastic) to produce a very strong structure. The glass-fibre material is layered in a mould and coated with the polyester resin; the resin sets without heat or pressure needing to be applied, and when it is set it is very strong. Advantages of GRP Excellent strength-to-weight ratio Excellent tensile strength Impact resistance High corrosion resistance Uses Sports car bodies Boat and canoe hulls Caravan shells Male mould GRP Smooth surface Female mould GRP Radiused corner Radiused corner Tapered to ease movement © Learning and Teaching Scotland 2006
Carbon-fibre reinforced plasticThis is a forming process similar to that used for GRP. Carbon fibre is embedded with resin to produce a material with a very good strength-to-weight ratio. It has good tensile strength with low density and it provides better corrosion resistance and fatigue performance than most metal alloys. Advantages of CFRP Excellent strength-to-weight ratio Excellent tensile strength Impact resistance High corrosion resistance Good aesthetic qualities Uses Racing-car bodies Fighter aircraft Bicycle frames Fishing rods Woven carbon fibres Carbon-fibre reinforced plastic © Learning and Teaching Scotland 2006
© Learning and Teaching Scotland 2006Smart materials What is a “smart” material? Unfortunately, there is no clear-cut answer or definition. Materials are usually thought of as “smart” when they seem to have a mind of their own – for example, those responding in some way to an environmental change. In reality, designers have at their disposal a fantastic range of modern materials, many of which have been deliberately created to provide useful properties and behaviour. Some materials seem to be “smarter” than other, but it all depends on the context in which they are used. Here we are going to look at four types of smart material: Shape memory alloys (SMAs) Polymorph (polycapralactone) Lenticular sheet Thermochromic film/pigment Click on appropriate star © Learning and Teaching Scotland 2006
© Learning and Teaching Scotland 2006Smart materials Shape memory alloys (SMAs) There is a number of alloys that exhibit useful memory characteristics. A combination of nickel and titanium (NITAL) is one of the most common. It can be heat treated to “remember” that when its temperature is raised to 70°C it should contract by 5%. Cooling to room temperature, it then relaxes to the original length. This alloy is increasingly used in place of bi-metallic strips in coffee makers, etc., because all the movement takes place around the temperature change point. As a wire, it is now being used in garments where body heat changes the characteristics of the fabric. © Learning and Teaching Scotland 2006
© Learning and Teaching Scotland 2006Smart materials Polymorph (polycapralactone) This relatively new polymer has an astonishingly low melting point of 62°C. It can therefore be melted underwater. As a solid, it has similar properties to an engineering nylon and can therefore be used for a wide range of prototype work where, after moulding by hand, the plastic is like the “real thing”. Pour a quantity of the sample into a glass or ceramic container (not plastic) and pour over very hot water. The granules will change from opaque to clear. When this happens, hook out the fused mass, allow the trapped water to cool to a comfortable temperature, and then squeeze out the water and mould the plastic. © Learning and Teaching Scotland 2006
© Learning and Teaching Scotland 2006Task 8 Using drawings to support your answer, describe how Polymorph could be used by a designer to develop the design of a screwdriver handle. State any advantages of using this material. ……………………………………………. …………………………………………….. © Learning and Teaching Scotland 2006
© Learning and Teaching Scotland 2006Smart materials Lenticular sheet Improvements in production technology have made it possible to produce sophisticated optical effects in a wide range of plastic films and sheets. Plastic Fresnel lenses, for example, are now common and inexpensive. Lenticular embossing has made it possible to print and animate many images on a single substrate. A similar technology is used to create stunning three-dimensional illusions on clear plastic sheet. If you place a piece of lenticular sheet lenticular side up on a darker surface, it will appear to be much thicker. The illusion is complete when you then place a coin over it. This will appear to sink into the material. © Learning and Teaching Scotland 2006
© Learning and Teaching Scotland 2006Smart materials Thermochromic film/pigment This material comprises a substrate – e.g. self-adhesive plastic film – which is then overprinted with thermochromic liquid crystal ink. As the temperature changes, the liquid crystals re-orientate and produce an overall colour change. This material is used to give temperature indications – e.g. on thermometers and temperature warning patches places on ICs. It is also used on batteries for testing their condition. Thermochromic pigment can be added to plastic or paint which can then be formed or applied to have the new properties. © Learning and Teaching Scotland 2006
© Learning and Teaching Scotland 2006Task 9 Using drawings to help your answer, describe how a safer design for a child’s bottle could be developed using thermochromic pigments in the plastic. © Learning and Teaching Scotland 2006
© Learning and Teaching Scotland 2006Task 10 Alloy Carbon fibre reinforced plastic Composite ferrous Glass reinforced plastic Hardwood Lenticular sheet Metal Nonferrous Plastic Polymorph Shape memory alloy Smart material Softwood Thermochromic film Thermochromic pigment Thermoplastic Thermosetting plastic Wood © Learning and Teaching Scotland 2006
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