1. RESISTANT MATERIALS REVISION Materials woods, plastics and composites and why products are made in these materials
Learning Objectives:
- To recap understanding of materials
- To know the properties of these materials

2. Revision timetable Date Topics Easter Hols
Complete the ‘Task Light’ prelim and look through the materials revision sheets online in prep for the lessons after Easter.
Thurs 21st May (ICT Content)
Production methods
Cad Cam- exam question
Thurs
23rd April
Materials - Plastics/ Wood/ Metal
Smart materials and composites
Practise exam paper
Joining and fixing
Screws bolts and nails, adhesives
Moulding and Forming
Thurs 7th May
6rs- exam questions
Social and moral
Thurs 4th June
(Psyc)
Levers pullies etc- computer room
Ergonomics and anthropometrics
Push Pull- exam question
Morning before the exam.
Feedback from paper and then revision in the sections that still need to be covered.
AQA Resistant Materials Exam Preparation
Monday June 6th is DDay and the RM Exam it will be in the afternoon and I have planned for a compulsory revision session beforehand during lessons 3&4.

3. Think about what is happening and why it is happening.

4. What’s the topic for today?

5. Whats the topic for today?
Types of wood and what they are used for.
Hardwood
Softwood
Manufactured boards
Types of wood (and trees), wood joints, adhesives and what we can make with these materials and components.
Left to right
Oak
Larch
Cedar
Elm
Pine
More...
Ash
Spruce
Beech
Holly
Sycamore
Birch

6. Can you spot the odd one out?
Left to right
Oak
Larch
Cedar
Elm
Pine
More...
Ash
Spruce
Beech
Holly
Sycamore
Birch

7. Do you know the difference?
1 Minute
We wouldn't be able to breathe
Birds would have no homes.
We wouldn't have any wood
The world could become a desert.
We would have very little rain.
Why are some woods called hardwoods and some called softwoods?
Is it because they are harder?
No.
Can you give an example of a hardwood that is soft?
Why is softwood cheaper? Because evergreens usually grow faster.
What are softwoods often used for? Window frames, floorboards.
Why are hardwoods usually more expensive? Because broadleaves grow slowly and usually stop growing in the winter.
What are hardwoods often used for? High quality furniture, interior woodwork for example bannisters.
What are manufactured boards?
BBC Hardwoods and Softwoods activity

8. Do you know the difference?
Coniferous trees are evergreen, needle-leaved, cone-bearing trees.
Grow fast all year and produce cheap softwoods.
Broad leaf deciduous trees often loose their leaves in winter.
Grow slowly, usually stop growing in winter and produce expensive hardwoods.
1 Minute
We wouldn't be able to breathe
Birds would have no homes.
We wouldn't have any wood
The world could become a desert.
We would have very little rain.
Why are some woods called hardwoods and some called softwoods?
Is it because they are harder?
No.
Can you give an example of a hardwood that is soft?
Why is softwood cheaper? Because evergreens usually grow faster.
What are softwoods often used for? Window frames, floorboards.
Why are hardwoods usually more expensive? Because broadleaves grow slowly and usually stop growing in the winter.
What are hardwoods often used for? High quality furniture, interior woodwork for example bannisters.
What are manufactured boards?
Wood from trees only comes in relatively narrow widths, due to the sizes of tree trunks.

9. Materials Research – Wood
Draw a line to the tree
F________________
S________________
C________________
Coniferous trees are …………………., needle-leaved, cone-bearing trees, such as ………………., ……………….. and …………………. .
Broadleaf ………………. trees often loose their leaves in winter, such as ……………….., ……………… and …………………..
Grow ……………….., usually stop growing in winter and produce expensive ………………….
Grow ……………….. all year and produce cheap ………………….
Often used for high quality furniture, interior woodwork, for example ………………….
Often used for window frames, ………………… and …………………… trees.
The problem: Wood only comes in relatively narrow widths, due to the sizes of tree trunks.
The solution:
1 Minute
We wouldn't be able to breathe
Birds would have no homes.
We wouldn't have any wood
The world could become a desert.
We would have very little rain.
fast pine spruce deciduous oak beech balsa slowly
hardwood softwood Floorboards Christmas evergreen cedar beech

10. Materials Research – Wood
Draw a line to the tree
Forest
Stewardship
Council
Coniferous trees are evergreen, needle-leaved, cone-bearing trees, such as pine, cedar and spruce. .
Broadleaf deciduous trees often loose their leaves in winter, such as oak, beech and balsa.
Grow slowly usually stop growing in winter and produce expensive hardwood.
Grow fast all year and produce cheap softwood.
Often used for high quality furniture, interior woodwork, for example bannisters.
Often used for window frames, floorboards and Christmas trees.
The problem: Wood only comes in relatively narrow widths, due to the sizes of tree trunks.
The solution: Manufactured Board – Small or large pieces of wood put together to form different size pieces.
Teacher sheet
Which is which? Are coniferous trees the same as evergreen trees? Most coniferous trees are evergreens, but some deciduous trees are evergreens as well. Evergreen trees keep their leaves in all seasons and lose them gradually. However, some broad, flat-leaved deciduous trees in the south also keep their leaves year-round. So, there you have it! Most coniferous and some deciduous trees are evergreens.
Why are some woods called hardwoods and some called softwoods?
Is it because they are harder?
No, it’s the type of tree they come from.
Can you give an example of a hardwood that is soft?
Balsa
Why is softwood cheaper?
Because evergreens usually grow faster.
What are softwoods often used for?
Window frames, floorboards.
Why are hardwoods usually more expensive?
Because broadleaves grow slowly and usually stop growing in the winter.
What are hardwoods often used for?
High quality furniture, interior woodwork for example banisters.
What are manufactured boards?
Small or large pieces of wood put together to form different size pieces.
1 Minute
We wouldn't be able to breathe
Birds would have no homes.
We wouldn't have any wood
The world could become a desert.
We would have very little rain.

11. pren How can we buy sustainable wood? Buy from local suppliers!
A wood commonly grown in Wales is Douglas Fir, which is a pine tree.
Forest Stewardship Council
Promote the responsible management of forests worldwide
Does anyone know the welsh word for wood?
Look for the stamp!
pren

12. Manufactured Boards Manufactured boards are timber sheets which are produced by gluing wood layers or wood fibres together. Manufactured boards often made use of waste wood materials. Manufactured boards have been developed mainly for industrial production as they can be made in very large sheets of consistent quality. Boards are available in many thicknesses.
How many man made boards do you know the names of?
Manufactured Board properties:
Manufactured Board properties: • Manufactured boards often made use of waste wood materials. • Saw dust is used to make MDF and hardboard. • The saw dust is held together with glue. • Boards are inexpensive so are often used as instead of real woods. • Manufactured boards do however do not look as good as real woods look. • Manufactured boards are often covered with a thin layer of real wood which  is called veneer this improves their appearance.

13. Manufactured board types
Grain image
Board Uses
Example product
MDF -
Plywood -
Chipboard -
Blockboard -
Hardboard -

14. Manufactured board types
Grain image
Board Uses
Example product
MDF - Smooth, even surface. Easily machined and painted or stained. Also available in water and fire resistant forms. A manufactured board.
Used mainly for furniture and interior panelling due to its easy machining qualities. Often veneered or painted.
Plywood - A very strong board which is constructed of layers of veneer or piles which are glued at 90 degrees to each other. Interior and exterior grades are available. A manufactured board.
Used for strong structural panelling board used in building construction. Furniture making. Some grades used for boat building and exterior work.
Chipboard - Made from chips of wood glued together. Usually veneered or covered in plastic laminate. A manufactured board.
Used for kitchen and bedroom furniture usually veneered or covered with a plastic laminated. Shelving and general DIY work.
Blockboard - Similar to plywood but the central layer is made from strips of timber. Good for shelves and worktops. A manufactured board.
Used where heavier structures are needed. Common for shelving and worktops.
Hardboard - A very cheap particle board which sometimes has a laminated plastic surface. A manufactured board.
Used for furniture backs, covering curved structures, door panels.

15. Give three advantages of using Medium Density Fibreboard (MDF) instead of solid
natural timber.
Explain each of your answers.
Advantage:
Explanation:
[2 marks]
Advantage:

16. Plastics Thermoplastics Thermosets
There are many different types of plastic and can be split into two groups (not including the composites :
Thermoplastics
Thermo plastics are made from long chain polymers, joined by weak chemical bonds. When the plastic is softened by heat the bonds break making the plastic ‘semi fluid’ and able to be shaped. As the plastic cools, new weak bonds form and the shape will be fixed. Because no chemical reaction has taken place this process can be repeated many times, making them recyclable, however excessive heat will permanently damage the chemical structure.
Thermosets
Thermosets or thermosetting plastics are plastics which are converted into their final form by heat. Once set, they cannot be softened by further heating as they undergo a chemical change. They have strong chemical bonds that hold the long chains together. These make thermosets heat resistant but not recyclable. It is difficult to make products by extrusion or injection moulding as they harden as soon as heated. Manufacturing methods include casting, moulding and laminating.

17. And also you could include…….
Composites
Composites are when materials are combined to achieve specific advantages. Examples of composites are Kevlar, GRP (Glass reinforced plastic), Graphite and Carbon Fibre. These are used extensively for sporting uses e.g Bike parts, motor racing car bodies and tennis rackets.

18. Thermoplastics - Polythene
High Density Polythene (HDPE) is tough and can be blow moulded (bottles for bleach and shampoo) injection moulded (toys and buckets) and extruded (piping)
Low Density Polythene (LDPE) is Made into thin film (Carrier bags, wiring insulation and squeezy bottles)
Acrylonitrile Butadiene Styrene (ABS) is strong, tough, scratch resistant and resists heat and chemicals. It is injection moulded to make Lego bricks and is used extensively for household appliances like Kettles, vacuum cleaners and housings for cameras and telephones.
Polychloroethene / Polyvinyl chloride (PVC) can be plasticised by different amounts to make a wide range of products (window frames, gutters, disposable pens, razor handles and credit cards) It is strong, stiff and chemical and weather resistant.

19. Thermoplastics - Polymetylmetacrylate (PMMA)
Polypropylene (PP) is versatile and flexible without breaking, and can withstand variable temperatures (yoghurt and butter tubs, crisp packets, garden furniture and car bumpers)
Thermoplastics - Polymetylmetacrylate (PMMA)
Polymethylmetacrylate (PMMA) is better known as Acrylic and is often used as a glass substitute. Acrylic is strong and a good insulator, but scratches easily (used in street signs, baths and spectacles). It is suitable for Vacuum forming, line bending and blow moulding
Polystyrene (PS) is used to make vending cups and model kits. It is light, transparent but quite brittle. It is vulcanised to make High Impact Polystyrene (HIPS) This is used for Vacuum forming in thin sheets, which are cheap and easy to work with. Expanded Polystyrene (EPS) is used as thermal insulation for packaging and food cartons. It is 90% air.

20. Thermosets - Epoxy Resins
Thermosets - Melamine Formaldehyde (Formica)
Thermosets - Urea Formaldehyde (Bakelite)
Urea Formaldehyde (Bakelite) is hard and brittle and a good insulator (Used for electrical plugs, sockets, switches & toilet seats)
Melamine Formaldehyde (Formica) is scratch, water and stain resistant and is used as a laminate in kitchen work surfaces. When plasticised it is called melamine (Used for children’s cups and dishes)
Thermosets - Phenol
Epoxy Resins which are mixed with a hardener and left to set. They can be used to make adhesives and flooring.
Phenol Formaldehyde is tough and heat resistant often black in colour. (Used for saucepan handles)
Thermosets - Epoxy Resins

21. This activity is about plastics.
Use your text book to help you answer the following questions (5 Minutes)
Where does plastic come from and explain how it is made
…………………………………………………………………………………...……………..………………………………………………………………………………………..
Explain what a thermoplastic is ………………………………………………………………………………………………………………………………
Explain what a thermosetting plastic is ………………………………………………………………………………………………………………………………
Danny wants to stick together 2 pieces of acrylic, what glue could he use?
……………………………………………………………… .………………………………………………………….....
He now wants to finish the pieces of acrylic to a high standard, what could he do?
……………………………………………………………… …………………..……………..…………………………… ………………………………………………………………

22. Using the text books or the internet answer the following questions
1, What are the positives for using plastics?
__________________________________________________________________________________________________________________________
(2 marks)
5, What are the negatives?
3, Wooden toys have been replaced over the years with plastic ones, why do you think this is?
______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
(5 marks)

23. Composite materials
Composite materials are formed by combining a reinforcing material such as wood pulp, and a bonding agent, such as glue. The wood pulp is made from the waste from cutting solid wood. MDF and GRP are examples of composite materials.
TRUQ
Copy out page 48 in the OCR book
Glass reinforced plastic
Carbon Fibre Reinforced plastic

24. Properties of Materials
Get online and you have (20 mins) to create a mind map explaining properties of materials and show examples
You must use the following headings and you can use words, sentences and images to explain each one.
Strength
Hardness
Plasticity
Properties of Materials
Durability
Brittleness
Toughness

25. Images for what products are made from and why!
Material…………………………..
(2 marks)
Reason…………………………………………………………………………………………
(1 mark)
Material…………………………..
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Material…………………………..
(2 marks)
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Material…………………………..
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Material…………………………..
(2 marks)
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Material…………………………..
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(1 mark)

26. Material…………………………..
(2 marks)
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Material…………………………..
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Material…………………………..
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Material…………………………..
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Material…………………………..
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