Some revision websites to test you. size/design/resistantmaterials/ ment/new/tca/step2/213847/

Assessment revision Make sure you revise for Theory paper and Design paper Theory paper – Important information One hour Only answer one question from Section B – Resistant Materials questions Design paper Design paper – Important information One hour 15min Only answer one question (Answer the resistant materials question!!!)

Year 10 theory WeekSyllabusActivities Part 2 - Resistant Materials Section 1: Practical applications design and make practical products Types of material understand the physical and working properties and application in relation to plastics, woods and metals Plastics – thermoplastics (nylon, polythene, polyvinyl chloride (PVC), acrylic, polystyrene, polypropylene) physical and working propertieslamp, thingy – thermosetting plastics (polyester resin including GRP, melamine, urea, formaldehyde and phenol formaldehyde) physical and working properties Woods - natural timbers (soft wood and hard wood) - focus on just main ones. classification, properties and usesthingy Process - understand why timber is seasoned and how to care for timber during storage and constructionthingy Manufactured boards: plywood, blockboard, chipboard, hardboard and MDF classification, properties and useslamp/ pewter Metals - show a working knowledge of the following metals: – ferrous metals (mild and high carbon steels) – non-ferrous metals (aluminium, duralumin and other common casting * alloys (copper and its alloys, zinc, lead and tin)pewter

Section 2 - Preparation of materials * What types of materials can you buy - in original forms, types and sizeslamp * cutting by use of hacksaw, guillotine, tenon saw, cross-cut saw, panel saw and portable power toolslamp/pewter understand the use of datum surfaces/lines/edges and be able to produce them by planing or filing explain the preparation for machine processes and safe methods of securing materials to work surfaces, work tables, faceplates, chucks and between centres on a lathe * Setting/marking out - measure and/or mark out work using ruler, pencil, marker pen, scriber, try square, bevel, dot/centre punch, dividers, marking gauge, cutting gauge and mortise gaugethingy accurately measure using a micrometer and a vernier gauge Section 3a - Shaping - Deforming/reforming (processes) bending, simple casting, lamination; vacuum forming; blow moulding; injection moulding;extrusion Section 3b - Shaping - Wastage/addition (produce require shape, form or contour – use hand snips, saws, files, basic planes and abrasive cutterslamp, thingy – simple hole boring by hand or machine including pilot, clearance,lamp tapping, countersunk and counterbored holes – use taps and dies for screw cutting by hand – use planes, chisels, gouges, saws, files and rasps lamp, thingy, pewter – use abrasive mops, discs and beltslamp, thingy

Section 4 - Special treatments (processes that change molecular structure of a material making it more or less suitable for the task it has to perform). – work hardening – annealing all metals – case hardening of mild steel – hardening and tempering tool steel (HCS) understand the term plastic memory and its significance understand steaming and bending of timbers and have knowledge of adhesives’ curing times and strengths Section 5 - Joining and assembly (join parts of a design structure permanent or temporary) understand methods of carcase, stool and frame constructionThingy, lamp using permanent and temporary joints use holding devices, formers and jigs to assist joining and assembly understand the use of KD (knock-down) fittings for use with modern materials such as veneered chipboard use a variety of fittings and adhesivesthingy, lamp Section 6 - Finishing (surface treatments on materials) Finishes - oils, paints,lacquers, stains, satin polishes, dipcoatingthingy, lamp be aware of surface finishes available for both interior and exterior usethingy be aware of the special finishes available that will prevent corrosion or stains, or withstand heat or liquids

Materials Revise physical properties and working properties and application in relation to plastics, woods and metals. Thermoplastics (nylon, polythene, polyvinyl chloride (PVC), acrylic, Polystyrene, polypropylene) Question: Give examples of products made for each thermoplastic and one of the properties that makes it a good use of material. Thermosetting plastics (polyester resin including GRP, melamine, urea, formaldehyde and phenol formaldehyde) Question: Give examples of products made from each thermosetting plastic and one of the properties that makes it a good use of material. Classification, properties and uses of natural timbers. Show a working knowledge of the following manufactured boards Plywood, blockboard, chipboard, hardboard and MDF. Question: Classification, property and use of MDF. Show a working knowledge of the following metals: Ferrous metals (mild and high carbon steels) Question: Non-ferrous metals (aluminium, duralumin and other common casting alloys, copper and its alloys, zinc, lead and tin) Question:

Thermoset plastics Polyester resin – With carbon fibre /audi-carbon-ski-update.html

Wastage/addition and joining methods Select and perform the following forms of cutting and removal of material, and joining and adding to a material to produce the required shape, form or contour: – use hand snips, saws, files, basic planes and abrasive cutters – simple hole boring by hand or machine including pilot, clearance, tapping, countersunk and counterbored holes – use taps and dies for screw cutting by hand – use planes, chisels, gouges, saws, files and rasps – use abrasive mops, discs and belts Show tools: Pilot hole, Countersunk hole, Taps and dies - Page 64/65 Activity: Students draw isometric drawings showing how two pieces of two by one pine can be joined using – nails, screws (look at two types of screws – slot and phillips head), nuts and bolts Activity: Students draw isometric drawings showing how two pieces metal can be joined using nuts and bolts, rivets (page 71), do sketch activity. Milling machine and CNC milling Question: 1. Draw a simplified diagram of the vertical miller and label all the important parts. 2. Explain the need for safety when using this type of machine. You may wish to describe the type of safety clothing required. 3. Describe how you could use a vertical miller in one of your projects.

Shaping - Deforming/reforming understand the following processes: bending, simple casting, lamination; vacuum forming; blow moulding; injection moulding; extrusion Watch videos: Questions: Vacuum forming (check answers) -

Case study: Cutlery tray What forming/reforming process could be used to make this product? What plastic would this product be made from? Draw what the former would look like in isometric. What material would the former be made from and why? How would we make the former from on sheet of MDF. List factors to consider for the former in order to have a successful vacuum form.

Joining and assembling methods Wood joints – edge joints Ways of assembling moving parts – using hinges Piano hingeTee hinge Other examples of hinges dent.com/joints/hinge1.ht m Question: Draw the hinge types and list two products that would include each hinge. Tongue and groove joints, biscuit joints Question: Draw the edge joints and name two products that would join wood in this method

Starter activity – link up the different materials to adhesive types

Joining and assembly understand methods of carcase, stool and frame construction using permanent and temporary joints Show example products and talk about joints used – screw threads, rivets, screws, nuts and bolts Movie on riveting: Knock down fittings, permanent joints and adhesives, welding metals.

Setting/marking out measure and/or mark out work using ruler, pencil, marker pen, scriber, try square, bevel, dot/centre punch, dividers, marking gauge, cutting gauge and mortise gauge Activity – collect images of tools:

Special treatments understand how the following processes can change the molecular structure of a material making it more or less suitable for the task it has to perform: – work hardening – annealing all metals – case hardening of mild steel – hardening and tempering tool steel (HCS) Find videos and research in workbooks:

Creating surfaces understand the use of datum surfaces/lines/edges and be able to produce them by planing or filing explain the preparation for machine processes and safe methods of securing materials to work surfaces, work tables, faceplates, lathe chucks and between centres on a lathe Find video: on using a wood or metal lathe

Joining and assembly Use holding devices, formers and jigs to assist joining and assembly Draw examples of jigs

Working with metals Bending is a process by which metal can be deformed by plastically deforming the material and changing its shape. Activity – find the other types of bending with metals. Pipe bending html

Finishing and protecting materials be aware of a range of different finishes including oils, paints, lacquers, stains, satin polishes, dipcoating Activity: Watch video - dipcoating

Finishing and protecting materials be aware of surface finishes available for both interior and exterior use be aware of the special finishes available that will prevent corrosion or stains, or withstand heat or liquids Activity – answer questions on metal finishing.