2. Hello and welcome to The Chase!
Can a class of pupils from Holy Trinity 3-16 school beat some of the school’s finest Engineering brains?

3. Play as a class to answer as many questions as possible in the time limit.
Work together as a table; write your groups answer on your whiteboard and hold up as soon as possible!

4. Time to face the chaser… But who will you be up against today?

5. ????

6. It’s time to face the Chaser!
Mr Mellor

7. The Chase is on!

8. Name a polymer suitable for injection moudling?
Write your groups answer on your whiteboard and hold up as soon as possible!
Name a polymer suitable for injection moudling?
Polystyrene, Polypropylene, ABS, Nylon.

9. Name three properties that make ABS suitable for injection moulding
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Name three properties that make ABS suitable for injection moulding
Rigid, Opaque, tough, gloss finish, texture possible

10. Name a suitable metal to manufacture gears from?
Write your groups answer on your whiteboard and hold up as soon as possible!
Name a suitable metal to manufacture gears from?
Low carbon steel, medium carbon steel.

11. Write your groups answer on your whiteboard and hold up as soon as possible!
What would you do to low carbon steel to increase it’s life when made into a set of gears?
Case harden it, do not accept harden only as low carbon steel only hardens about 2mm depth.

12. Briefly describe the heat treatment process?
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Briefly describe the heat treatment process?
Heat up to cherry red, expose to carbon rich environment, cool with water or oil. Can reheat to blue and quench in water to remove brittleness.

13. What is the gear ratio equation?
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What is the gear ratio equation?
Number of teeth on the second gear divided by the number of teeth on the first gear.

14. Name a metal suitable for casting into a skateboard truck?
Write your groups answer on your whiteboard and hold up as soon as possible!
Name a metal suitable for casting into a skateboard truck?
Aluminium, Aluminium alloys, pupils must say something about steel axles or they will only get 0.5 points

15. What properties should a skateboard truck material have?
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What properties should a skateboard truck material have?
Strong, lightweight, rigid, corrosion resistant, suitable for casting (low-ish melting point)

16. What material would you use for bicycle wheel rims?
Write your groups answer on your whiteboard and hold up as soon as possible!
What material would you use for bicycle wheel rims?
Aluminium, Aluminium alloy, Steel or steel alloys, composite material such as Carbon Fibre. Do not accept metal, wood or plastic

17. Identify a suitable material for bicycle hand grips?
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Identify a suitable material for bicycle hand grips?
Rubber, neoprene, Silicon.

18. Write your groups answer on your whiteboard and hold up as soon as possible!
Give three reasons why your chosen material is suitable for bicycle hand grips?
Easily moulded, Durable, Comfortable, Resistant to moisture/sweat, can be personalised.

19. Why do we both harden and temper steel?
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Why do we both harden and temper steel?

20. Give an example of a composite material?
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Give an example of a composite material?

21. Write your groups answer on your whiteboard and hold up as soon as possible!
Give at least two advantages of making bicycle frames from a composite material?
Lightweight, high strength to weight ration, Decorative/Aesthetically pleasing, Self finishing, Can be layered up to maximise strength

22. Write your groups answer on your whiteboard and hold up as soon as possible!
Give at least two disadvantages of making bicycle frames from a composite material
Time consuming to manufacture, Expensive, Higher level of skill required to manufacture, More difficult to repair if damaged, cannot be recycled.

23. Name an engineered wood?
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Name an engineered wood?
Accept MDF, Plywood or chipboard

24. Write your groups answer on your whiteboard and hold up as soon as possible!
Explain why plywood has high strength compared to other engineered wooden sheets?
It has the grain running at 90 degrees to each other for maximum strength.

25. Give at least two types of finishing metal other than polishing?
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Give at least two types of finishing metal other than polishing?
Powder coat, zinc plating/coating, spray painted, galvanised, anodised (aluminium)

26. Write your groups answer on your whiteboard and hold up as soon as possible!
Under what circumstances would you use a thermoset plastic over a thermoplastic?
One where the part would be exposed to high temperatures, bonus point if they say a thermoplastic would melt

27. Write your groups answer on your whiteboard and hold up as soon as possible!
Give at least two different types of form you can buy plastic material in?
Pellets, sheet, tube, bar, flat

28. Give a reason why cutlery is manufactured from stainless steel
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Give a reason why cutlery is manufactured from stainless steel
It does not corrode, it requires no additional finishing.

29. Give at least two reasons why nuts and bolts are zinc plated?
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Give at least two reasons why nuts and bolts are zinc plated?
They will rust otherwise, it makes them look better aesthetically. They will last longer outside when exposed to the weather

30. Give one disadvantage of hardening steel?
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Give one disadvantage of hardening steel?
Material becomes brittle, Labour intensive, hard to bend/shape

31. Give at least two reasons why steel is hardened?
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Give at least two reasons why steel is hardened?
Increases wear resistance, Greater durability, increases abrasion resistance, less easy to scratch, more suited to a range of applications

32. Give the main reason why mild steel can only be case hardened?
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Give the main reason why mild steel can only be case hardened?
The hardening only penetrates 2mm maximum due to the lack of carbon in the mild steel itself.

33. What is the difference between ductility & malleability?
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What is the difference between ductility & malleability?
Ductility is the ability to be deformed under tensile stress whereas malleability is the ability to be deformed under compressive stress.
IE drawing copper wires = ductility, producing car body panels by pressing sheet is malleability

34. Briefly explain the material property, toughness?
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Briefly explain the material property, toughness?
The ability of a material to be deformed without fracturing.

35. Briefly explain the material property, hardness?
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Briefly explain the material property, hardness?
The ability of the material to withstand surface indentation or scratching.

36. What is the more common name for GRP?
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What is the more common name for GRP?
Fibre glass

37. What properties make GRP suitable for manufacturing boat hulls?
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What properties make GRP suitable for manufacturing boat hulls?
It is light, cane be made into any shape and can be easily repaired.

38. Now it’s your turn to come up with the questions…
Write a simplifying expression or substitution question on your whiteboard for the chaser to answer (you must be able to answer it!)
Caught!

40. CONGRATULATIONS!
You beat The Chaser!

42. Class, you have been caught and for you… The Chase is over!